How to connect Resanta welding

How to operate a resanta welding machine

You bought a welding machine and want to learn how to weld with an inverter for beginners.

There is no need to be afraid of difficulties! The inverter machine is easy to use; anyone without experience or knowledge can master the welding process in a short time.

Equipment, equipment, safety precautions

Safety precautions. Welding production is associated with electrical voltage, or in common parlance - current. The current is invisible, but can kill a person.

We check the welding cables for serviceability and connect them to the inverter equipment. Return cable with a clothespin on metal to the negative connector. Cable with electrode holder to connector +. We insert the electrode into the electrode holder.

When connecting the device to the network, visually evaluate the current-carrying cables for serviceability. After making sure that the cables are in good condition, we plug in the plug into the socket and the toggle switch on the device, having previously set the current regulator to the lowest value. If the cooling fan starts working smoothly, without crackling or noise, then everything is fine.

Metal weight. When connecting heavy structures, take precautions. If multi-ton products collapse, they can lead to death or disability.

Equipment. Welding production involves high temperatures. The welder must have:

• canvas mittens (gaiters);
• robe (special suit);
• mask with a light filter;
• respirator for work in confined spaces;
• boots with rubber soles.

Gaiters are used when welding at heights, when arms are raised up, and mittens in other cases.

• welding machine;
• hammer;
• brush;
• electrodes.

Electrodes are selected according to the metal (carbon content, additives) and diameter, depending on the thickness of the metal and the technical characteristics of the inverter.

Inverter Welding Basics

For beginners, experienced welders advise attaching the holder cable to the body, pressing it with the elbow of the arm and wrapping it along the forearm (from the elbow to the hand), and taking the holder in your hand. This way the shoulder joint will pull the cable, and the arm and hand will remain free.

The method will help you manipulate your hand with ease.

Correct placement of the cable on the forearm. You should not work with bare hands.

If you simply take the holder in your hand without wrapping the cable around your forearm, then during the welding process your hand will get tired and wrist movements will cause the cable to dangle. Which will affect the quality of the welded joint.

How to cook using inverter welding correctly? We set the welding current on the machine according to the diameter of the electrode, the type of connection and the welding position. Setup instructions are available on the device and the electrode pack. We take a stable stance, move our elbow away from the body (no pressing), put on a mask and begin the process.

For beginners, it is better to start welding with an inverter with metal workpieces larger than 20 cm.

It is known that a beginner, putting on a mask and lighting an arc, stops breathing, trying to boil the entire length of the workpiece in one breath. With short products, you will develop the habit of cooking in one go. Therefore, practice on long workpieces, learning to breathe properly when welding.

Workpieces (plates) on the work table can be placed in a horizontal plane - vertically towards you or horizontally, it makes no difference.

At the beginning of welding, place the electrode clamped in the holder at an angle of 90 degrees (perpendicular) and move it towards the seam by 30-45 degrees. Light the arc and start moving.

1. If welding is performed at an angle backwards, then the tilt of 30-45 degrees goes towards the seam.
2. If the connection occurs at an angle forward, then the electrode is tilted away from the seam.

The distance between the surface to be welded and the electrode is 2-3 mm, imagine that you are running a pencil along a sheet of paper.

Please note that when welding, the electrode decreases as it burns - gradually bring the melting rod closer to the surface at a distance of 2-3 mm and maintain an inclination angle of 30-45 degrees.

Watch a useful video on how to learn how to weld with electric welding for beginners:

How can a beginner learn to weld with a welding inverter?

First we learn to light and hold an arc. Feel the edge when to bring the electrode closer to the surface to be welded during combustion so that the arc does not interrupt.

The electrode is ignited in two ways:

The new electrode ignites easily. A slag film appears on the working rod, preventing ignition. You just need to tap longer to break the film.

1. To facilitate arc ignition, inverter devices have a built-in Hot Start function.
2. If a beginner quickly brings the electrode closer to the surface, the Arc Force function (arc force, anti-sticking) is activated, increasing the welding current, preventing the electrode from sticking.
3. If the melting rod gets stuck, the Anti Stick function cuts off the current, preventing the inverter from overheating.

What is arc force on a welding inverter and how to use it.

It is better for a beginner to first learn on a thread seam; the electrode is held smoothly, without oscillatory movements.

After mastering thread technology, proceed to welding metal with oscillatory movements. Which are used on thick metal for heating, holding the electrode at a certain point using movements - herringbone, zigzags, spiral or your own method.

Types of oscillatory movements

At the beginning of the connection, we carry out several movements from left to right, forming a weld pool and go along the seam making oscillatory movements. The angle of inclination of the electrode is 30-45 degrees. After passing, we beat off the slag with a hammer and clean it with a brush. Take care of your eyes, wear glasses.

Tip: at the end of the weld, make oscillatory movements to the sides and move the electrode towards the deposited metal. This trick will add beauty to the welded joint (get rid of the crater).

how to weld corner joints, butt joints and overlap joints.

• single-pass (one pass replenishes the thickness of the metal);
• multi-pass.

A single-pass weld is performed on metals up to 3 mm. Multi-pass seams are applied for large metal thicknesses.

Welders check the quality of the seam with a hammer - they strike next to the seam. If the seam is smooth, without irregularities, then after the impact the slag flies off completely, there is nothing for it to catch on. It is important to select the correct temperature regime: an overheated seam (hot) will break, an underheated one - there is a risk of lack of penetration.

The current is selected based on the diameter of the electrode, in theory 30 A per 1 mm of electrode diameter.

Direct and reverse polarity when welding with an inverter

Let's consider polarity when welding with an inverter. With a DC connection, the movement of electrons is constant, which reduces spattering of molten metal. The seam is of high quality and neat.

The device has a choice of polarity. What is polarity is the direction of movement of electrons depending on the connection of cables to equipment connectors.

1. Reverse polarity when welding with an inverter - minus on the workpiece, plus on the electrode. The current flows from minus to plus (from the workpiece to the electrode). The electrode heats up more. Used for welding thin metals, the risk of burn-through is reduced.
2. Straight polarity - minus on the electrode, plus on the workpiece. Current moves from the electrode to the workpiece. The metal heats up more than the electrode. Used for welding thick metals from 3 mm and cutting with an inverter.

Source: https://crast.ru/instrumenty/kak-rabotat-svarochnym-apparatom-resanta

What kind of cable is needed for the Resanta Sai 220pn welding machine? — Website about

page » Articles about welding » Welding station » Equipment » Cable » Welding cable for inverter

Inverters are easy to use, compact, mobile, easy to connect, affordable, and suitable for beginners and experienced professionals. The popularity of this equipment requires the correct choice of cable for it. The article will discuss which cable is best to use for an inverter welding machine.

Welding cable design

The cable design includes the following elements :

• conductive copper core consists of many wires, the cross-section of which does not exceed 0.2 mm;
• covering can be made of rubber or rubber (natural or butadiene);
• The separating layer is made of a special transparent film that prevents the coating and core from sticking together.

Characteristics of welding cables

As noted earlier, the cable for the inverter must be highly flexible . In addition to this important property, electrical conductors are required to meet the following characteristics :

1.  Strength , i.e. resistance to mechanical stress: shocks and tears.
2. Resistance to temperature fluctuations, the ability to use the conductor in conditions of very low or fairly high temperatures.
3. Resistant to sunlight and moisture .
4. Immunity to mold and mildew .
5. Elasticity - minimal likelihood of bending.

There are few brands of conductors designed specifically for welding work. And there are only two types of cables that meet the above characteristics: KG and KOG.

Among craftsmen, the first type is in particular demand - flexible cable (KG). It should be used to connect mobile mechanisms to networks with alternating voltage up to 660 V with a frequency of 400 Hz . DC voltages up to 1000 V .

KOG is a particularly flexible cable, analogous to KG, indispensable when working in hard-to-reach places, ensures quick changes in the position of equipment and guarantees freedom of action for the performer.

It is recommended to use it for connecting electrode holders, automatic and semi-automatic installations to networks with alternating voltage up to 220 V with a frequency of 50 Hz or constant - up to 700 V.

If the performer is thinking about which brand of cable for the remote control of the welding inverter is more suitable, then you can choose KOG.

Each of these brands has the following varieties, which are clearly distinguishable if you look at the markings:

• KOG-HL/KG-HL - cold-resistant , resistant to extremely low temperatures, down to -60°C;
• KOG-T/KG-T - tropical , resistant to various types of mold formations, operating temperature should not exceed +55°C.

You should also pay special attention to the following varieties:

• KGn has non-flammable insulation and should be used in fire hazardous conditions.
• KOG-U is used only in temperate climates , in the temperature range from -45 to +40°C.

Many performers have equipment of specific brands or manufactured by specific factories. Welders are especially often concerned with the question of which welding cable to choose for the Resanta inverter? Both brands: KG and KOG would be a suitable choice in such a case.

Section selection

Choosing the right wire cross-section is the main task. The conductivity depends on the cross-section, which, in turn, has a direct impact on the speed of work and the quality of the formed connection. The cable must comply with the technical specifications of the inverter.

Conductors with a small cross-section (up to 7 mm2) will be a suitable option for small devices that operate from a household electrical network of 220 V.

Also for inverter-type units, cables with a cross-sectional area of ​​10 are suitable; 16 and 25 mm2. More detailed information about the characteristics of the KG and KOG conductors is provided in the linked articles.

Important! Use of unsuitable wire may result in overheating, fire and/or short circuit, which may cause equipment failure or fire.

When connecting conductors to the inverter, you must adhere to the following rules :

• connection is made using special lugs , insulation of connections is required;
• The cords should be connected to each other by crimping ;
• When connecting to connectors and electrode holders, polarity must be observed ;
• The cables the power of the existing device.

It is not always possible to perform crimping when connecting two pieces; some practitioners use the following method of splicing cables.

Is it possible to extend the welding cable on the inverter?

The length of the wire is selected based on the magnitude of the output current load and its losses along the length. The longer the cable, the higher the losses and the lower the current. In order to achieve balance, the performer has to set an increased voltage, which can lead to a change in the arc and equipment breakdown. Therefore, excessive extension of the inverter welding cables is not recommended.

On the other hand, it is worth familiarizing yourself with the experience of a practicing welder on YouTube.

Important! The suggestion to use a welding cable extension for an inverter should be treated with suspicion and skepticism.

However, it is worth noting that manufacturers do not set any restrictions on the extension of wires. A special connector for the welding cable to the inverter will help you make the connection efficiently, easily and quickly. More information about connectors of various types is presented in the article “Connector for welding cable”.

Consequently, each performer will be able to independently answer the question posed in the title.

Where to buy electrodes of various brands

Choose manufacturers and sellers of welding electrodes by clicking on the link below to the page of our catalog of companies.

Select a company

Source: https://orensbyt.ru/elektrika-v-kvartire/kakoj-nuzhen-kabel-dlya-svarochnogo-apparata-resanta-sai-220pn.html

Welding inverter Resanta SAI-250

Passport (instructions) Resanta SAI 250PN . passport-instrykciya-resanta-sai-_250 DOWNLOAD

Resanta SAI-250PN is a welding inverter, one of the most popular on the market.

All models of inverter machines " SAI-250 PN " received protective mechanisms against temperature overheating, and also have the anti-sticking function "ANTI STICK", the ability to adjust "ARC FORCE", and the hot start " HOT START ".

Resanta Sai 250

Packaging, power cables and appearance of the Resanta Sai-250

This device is easy to set up and operate. Thanks to the use of all the necessary functions such as: anti-sticking of the electrode, easy ignition of the arc, high VA value.

These parameters greatly facilitate the process of joining metal, allowing even an inexperienced welder to achieve a good metal seam. The SAI-250PN inverter welding machine is lightweight and small-sized, and has a well-adapted carrying handle on top.

It will be easy for the welder to install and will make him mobile on the job site.

Handle on top of the device

Characteristic features of Resant

Resanta SAI-250PN can weld at reduced voltage. In case of network fluctuations, the inverter shows its best side, providing high stability of the set parameters of the welding process.

The inverter machine is designed for manual welding with a coated electrode using direct current.

Resanta 250 professional is an energy-efficient welding machine due to its high energy conversion efficiency.

If we compare SAI 250 with conventional transformers, then this type will benefit from the ease of setting parameters and maintaining a weld.

Settings panel and protective glass

Manuals and instructions for the inverter

Beginner's Guide to Arc Welding

Passport instructions for Resanta SAI 250PN .

Device delivery set

Cable with ground terminal for base metal

Cable with electrode holder for manual welding 2m.

Passport products

Inverter welding machine Resanta SAI 250PN directly

Measurement SAI-250

Resanta Sai 250: technical specifications

Possible voltage range, V 140-240

This will allow you to power the device from a regular household single-phase network.

Maximum possible current consumption, A 35

Possible open circuit voltage, V 80

Welding arc voltage, Volt 29

Current regulation range, A 10-250

Inverter load duration, % 70% 250A

Electrode diameter, mm up to 6, which also sets the inverter apart from its competitors;

Device protection class IP 21

Device weight, kg 6.7

Dimensions Resanta 250 dimensions, cm: 25 x 13 x 40 cm

Packaging (HxWxD), cm 43 x 17 x 29 cm, weight 8 kg

Firm Resanta

Country of origin People's Republic of China

Convenient on/off switching of the welder

Appearance and dimensions

The Resanta 250 welding machine has the highest power among the range of similar inverters. In addition, its small dimensions make it extremely convenient for transportation. The inverter can easily fit into the trunk of a car. It won’t be a significant burden as hand luggage either. This is especially true if you compare it with a conventional transformer.

Cables and sockets "Resanta SAI"

The Resanta-250 inverter is designed in a classic metal case with dimensions of 25 x 13 x 40 cm.

The front panels have a standard group of indicators and adjustment knobs for modern inverters. There are also working connectors, which include:

— “device overheating” indicator;

— “network” indicator;

— power sockets for connecting various welding cables .

— setting the welding current ;

In order to avoid overheating of the Resanta SAI-250 welding inverter, the developers equipped it with a forced air cooling system, since welding generates a large amount of heat inside the device. From the outside it is easy to notice the fan grille of this cooling system.

Setting the welding current

"Resanta-250" is no different from its relatives from other manufacturers in terms of its operating principle. First, the alternating voltage coming from a regular household network of 220V is converted into constant up to 400V, which is subsequently converted to a modulated high-frequency voltage. After which the step-down transformer reduces the resulting converted voltage to the required operating setting.

To improve the quality of welding work, as well as ease of use, this Resanta-250 model received a number of additional functions to ensure a good level of work.

Add-ons included: Arc Force function - adjustable arc force, "Anti Stick" and "Hot Start".

In order for the user to get a durable and high-quality seam from the very beginning of work, the creators of the inverter implemented the “Hot Start” . The essence of the function is as follows: at the moment the arc is ignited, the device supplies increased welding current, which immediately returns to normal. This makes the task of igniting the arc easier.

In addition, “Anti stick” should be mentioned. This function helps well to protect the electrode from a fairly common problem among welders - sticking of the electrode to the base metal.

Do not ignore safety rules when working with the device. If there is high humidity in the room, work should be abandoned, taking into account the electrical housing of the Resanta Sai 250.

During operation of the device, shavings and various metal dust quite often get in, which often leads to a short circuit. You should stop using grinders and other similar tools to drive the inverter. Don't forget about power cables, they also need care. Power cable length - 1.9 m Cable length with electric holder - 3 m

repair and review of the welding inertor "Resanta-250":

Resanta SAI-250 inverter circuit

Electrical circuit diagram of the welding inverter Resanta - 250 

Scheme RESANTA_SAI-250 DOWNLOAD

Cleaning the internal circuitry of the Resanta SAI-250

The welding inverter " Resanta - 250 " is made in a classic metal case and has on the front panel a number of indicators and adjustment knobs, as well as working connectors. These include: - "network" indicator; - "overheating" indicator; - current adjustment;

— power connectors for connecting welding cables.

Since when performing welding work, despite the inverter design of the unit, a significant amount of heat is generated, “ Rosanta-250 ” is equipped with a forced cooling fan, the grille of which is visible during external inspection of the product.

The principle of operation of the welding inverter "Resanta - 250" does not differ from similar devices from third-party manufacturers. The incoming alternating voltage of the household electrical network 220V is first converted to a constant voltage of 400V, which is subsequently changed to high-frequency modulated voltage. Next, a step-down transformer comes into operation, which lowers the converted voltage to operating voltage.

To improve the quality of work, as well as to obtain greater comfort during welding work, the welding inverter “Resanta - 250” “Anti Stick” and “Hot Start” functions

The “Anti stick” function, as the name implies, prevents the electrode from sticking to the surface of the materials being welded. That is, when the arc is ignited, the welding current automatically decreases, which is instantly restored after the electrode comes off.

And in order to get a beautiful and durable seam immediately after starting welding, the machine has the “Hot Start” function. In this case, at the moment the arc is ignited, there is a short-term increase in the welding current, which immediately decreases to the normal, required state.

Promotion of the resent with a screwdriver

When working with the Resanta-250 welding inverter, you must follow safety precautions. So, since the device is made in a metal case, it is strictly forbidden to use the latter in high humidity.

Do-it-yourself Resanta renovation

Chips and metal dust that get inside can damage the electronic part or even cause a short circuit. Therefore, the use of grinders and similar tools near the welding inverter is prohibited. And, of course, it is necessary to monitor the condition of the power and supply wires.

welding inertor "Resanta - 250":

Source: http://svarak.ru/oborydovanie/734/

Connecting a welding inverter

:

Each welding machine is equipped with a standard set of cables. Without them it is simply impossible to carry out any work. Therefore, the correct connection of the welding inverter is of great importance.

All such devices are equipped not only with two working cables, but also with another one through which power is supplied. Some difficulties may arise with the cables for connecting the electrode and the clamp that provides connection to ground. There are separate connectors with plus and minus for them.

Connection options may vary depending on the material used and the work conditions.

Preparation for work and connection

Once protective clothing, shoes, a welding mask and electrodes have been prepared, you can proceed to connecting the device. Due to the increased power of the equipment, it is necessary to become familiar with the characteristics and capabilities of the network used as a power source. As a rule, there are no special problems, since all household inverters are designed for 220 volts.

The only requirement related to safety is the installation of a machine with the necessary parameters. This will avoid negative consequences in the event of short circuits and other unforeseen situations.

Next, the welding inverter is placed at the workplace in compliance with certain rules and technical standards:

• The minimum distance from walls and large objects is 2 meters.
• Protective grounding is mandatory.
• There should be no flammable or explosive objects or substances nearby.
• For welding work, you should use a metal table or just a free platform.

Having prepared the workplace, you can connect the welding inverter. Each cable and wire is inserted into the desired inverter socket. An electrode is fixed in the holder, and a ground clamp is connected to the metal workpiece. Not only a household network of 220 V can be used as a current source, but also an industrial network of 380 V. In the absence of stationary networks, the use of a gasoline or diesel generator is allowed.

Electrical connection

When connecting a welding inverter to a home network, technical problems often arise. Therefore, this procedure must be performed correctly and extremely carefully, taking into account the peculiarities of local electrical wiring. The possible uninterrupted operation of the device should also be taken into account, with precise time intervals allocated for welding and technical breaks.

First of all, it is necessary to study the characteristics and type of outlet where the inverter is connected. Typically, when operating at maximum current, the inverter is capable of outputting 140 A. With such indicators, a 16 A socket is quite sufficient. Older houses still have 10-amp products and associated wiring, which may not withstand increased loads. You should check the presence and condition of safety plugs and automatic devices.

https://www.youtube.com/watch?v=8dR1RfoteHc

If so-called bugs are installed as protection, then as the load increases, their presence can cause serious consequences - short circuit, melted wiring, fire, etc. It may be necessary to install a new circuit breaker, taking into account the load that the converter adds.

In some cases, a so-called network sag may occur, when the voltage drops to 150 V or lower. This is the first sign of insufficient cross-section of network wires. If the voltage drops below the minimum permissible limit, then welding equipment cannot be connected to such a network.

When using an extension cord, the coiled wire must be unwinded to its full length. Otherwise, inductive resistance may occur in places where the twists are twisted, which, in turn, will lead to overheating of the insulation, even to the point of melting.

If winding cannot be avoided, it should not be too tight to ensure natural ventilation.

Power supply for inverter welding from a generator

If the facility is not equipped with a stationary electrical network, but welding is still required, you can use a gasoline or diesel generator. The most important thing is to correctly calculate the load so that both devices are optimally combined with each other.

It must be taken into account that any inverter contains coils, capacitors, electronic circuits and other elements that are considered reactive consumers with a power factor of about 0.7. When calculating the total power of the device, it is necessary to divide the active power by the power factor.

After preliminary calculations, hardware compatibility will look like this:

• With a welding current of 160 A, you can only work with electrodes with a largest diameter of 4 mm. The active power of such an inverter is 3.8 kW, and the total, taking into account the coefficient of 0.7, will be approximately 5-5.5 kW. Taking into account the 20% power reserve, a generator of at least 6 kW will be required.
• Welding current of 180 A allows work with 5 mm electrodes. Active and apparent power will be 4.8 and 7.5 kW, respectively. Therefore, the generator power should be no lower than 8-8.5 kW.
• If the welding current reaches 200 A, then such equipment needs a three-phase network. The diameter of the electrode increases to 6 mm. The total power of the inverter will be 11.5 kW, and the power of the three-phase generator will be no less than 15 kW.

Sometimes the question arises about the possibility of using a powerful welding device not to its full potential. Can a circuit for connecting an inverter to a generator with a lower power be used? Experts do not recommend making such a decision on your own; only a professional electromechanic can give a final conclusion.

It is also necessary to take into account the presence of additional options in specific equipment that require a short-term increase in power at the time of their use.

Selecting extension cord parameters

Often the power cable included with the inverter is too short and does not provide a welding connection so that it is located near the structures being connected. Therefore, welders are forced to use extension cables or carriers. They differ from similar household devices only in the increased power of the conductors.

From a technical point of view, an extension cord is nothing more than an additional section of the circuit from the inverter apparatus to the current source. Therefore, the well-known Ohm's law is quite suitable for calculations. With the same power of different connected consumers, the cross-section of the conductor directly depends on the length of the portable cable. The material should be metals with minimal resistivity.

Therefore, all modern conductors are made of copper. The insulation does not affect the electrical properties of the cable in any way, but during operation it is subjected to various mechanical loads. Its thickness should be as high as possible, in this case the cable will last much longer.

The choice of cross-section is made depending on the value of the welding current. The cable length and voltage are taken as the initial data for calculations. You should take into account the possible voltage drop in this area, which can cause overloads in the home network. It is mandatory to create a power reserve of at least 10%, eliminating the possibility of overheating of the conductors.

It is recommended to create extension cords of different lengths, divisible by 10 m, in the kit for the welding machine. It is better not to use short carrying cables. With optimal carrying sizes, it does not have a noticeable effect on the general condition of the circuit and the magnitude of its voltage. The cross-section of the cable used in the extension cord and the cross-section of the home wiring should be approximately the same. The use of household carriers to connect welding equipment is strictly prohibited.

How to connect an inverter in different polarity modes

Power cables have special terminals, designated plus and minus. Many novice users do not think about how to connect a welding inverter and connect the wires without taking into account the polarity and actual operating conditions.

Meanwhile, the difference is still present and it depends on the laws of physics, in accordance with which the movement of electrons occurs.

Having a negative charge, they move from minus to plus under any conditions, including when an inverter is included in this chain. The welding machine will work regardless of the terminal to which the electrode is connected.

However, the movement of electrons in each case will occur in different directions, and this will directly affect the workflow itself and the final result.

The direct polarity scheme involves connecting the plus to the workpiece (ground), and the minus to the electrode. An arc is formed between them, through which the welding current passes. With this connection, the anode is the part, and the cathode is the electrode. The weld seam will heat up more, about 700-1000 degrees more than the electrode.

With reverse polarity, on the contrary, the electrodes are connected to the positive terminal, and the part being welded is connected to the negative terminal. In this case, the electrode will heat up more.

The main factor in choosing polarity is the thickness of the workpieces being joined. A more massive metal requires stronger heating at the junction for better mutual penetration of molten particles. Thin materials, on the contrary, cannot be heated too much to avoid burn-through and an uneven weld.

Source: https://electric-220.ru/news/podkljuchenie_svarochnogo_invertora/2019-06-09-1700

Starting current of welding inverter

Inverters, or they are also called converters, are popular welding machines that are powered by autonomous generators (power plants) produced by manufacturers in a wide range.

Which generator is suitable for welding? What criteria or parameters should I pay attention to when selecting a generator model? How to competently and correctly select it? The reader will receive answers in this article.

The generator for the welding inverter is selected based on a very important characteristic of the converter - its power consumption. But this is not always enough, because...

not all characteristics of the power source are compatible with the data specified in the inverter data sheet.

Features of choosing a generator

Particular attention must be paid to such an important characteristic as the rated power of an autonomous generator. It should be selected with a large margin and directly depends on the specific model of the generator; you can find out more about the new products of gasoline generators at the link - http://www.tiberis.

ru/collections/generatory-elektrostancii-agregaty-benzinovye. It has been practically proven that for generators running on diesel fuel, it should be 50% higher than the power consumed by the inverter. For generators running on gasoline, this figure is within a wider range - 15 ÷ 25%.

The discrepancy between the operation of these two units is the result of the difference in the nature of their load. In an inverter it carries a capacitive component; in a generator it is designed for active-inductive consumers. As the current strength of the welding machine increases, the voltage increases and this occurs due to the capacitive component.

The generator develops current feedback, which should compensate for the voltage from the load. As a result, there is a large increase in voltage in the inverter module, which sometimes leads to damage to the equipment or it stops working altogether.

It is for this reason that generators with increased power are used for inverter-type welding machines. These can be generators of any type, but they must satisfy this important

requirement. If the generator power is not enough, then it is better to use an external electrical network when carrying out welding work to turn on the inverter unit. But in many cases this is not feasible. If there is no electrical network, you must use only an autonomous generator.

Power calculation

When calculating the required power that a power plant must have, it is necessary to use the technical characteristics of the converter. They must be indicated in the manufacturer’s passport of a specific model. Usually the passport indicates the limits of current regulation - from minimum to maximum. Based on this, the power (maximum) of the welding converter is calculated.

When calculating power, a special formula is used that helps to quickly make the necessary calculations. Take the maximum welding current of the inverter and multiply it by the welding arc voltage. The result obtained is divided by efficiency. inverter (the efficiency value is taken from the passport data). The result will be the maximum power of the converter.

But one feature must be taken into account - the inverter is usually never used to operate at maximum power. It operates at average power, which is calculated taking into account the on-duration (ON). The PV value is indicated in the product passport. Now all that remains is to multiply the resulting inverter power by PV. The result will be the average power of the device.

In conjunction with generators, it is best to use welding inverters that operate at reduced voltage; you can learn more about such devices on this website.

The calculation looks like this:

For example, the initial data for the inverter is as follows (we take the values ​​from the passport):

• regulation limits: I= 10 ÷ 180 A;
• U arc – 25 V;
• efficiency – 0.85;
• PV – 40% (0.4).

We substitute the data to calculate the maximum power of the converter:

180 x 25 / 0.85 = 5294.12 W or 5.3 kW

Determine the required average power:

5294.12 x 0.4 = 2117.65 W or 2.1 kW

It remains to calculate the required generator power. To do this, multiply the inverter power by the following coefficients:

•  1.5 - in case of choosing a diesel generator;
•  1.15 ÷ 1.25 – in case of choosing a gasoline-type generator.

In numbers, in relation to our example, it looks like this:

Power for generator:

2.1 x 1.5 = 3.15 kW,

2.1 x (1.15 ÷1.25) = 2.4 ÷2.6 kW

All these formulas are correct if the power consumed by the inverter is indicated in kW. But many manufacturers of high-quality generators indicate the power value in another unit of measurement - kVA. This is especially true for imported generators. The calculation then needs to be carried out taking this feature into account. Conversion from one unit to another is carried out using the following formula:

1kW = 1kVA x power factor

The power factor of inverters does not exceed 0.7 and is usually indicated in the passport.

By applying the above formulas, you can calculate the maximum permissible current the inverter can operate at.

Selecting a generator for a welding inverter of a certain model, for example, for the widely used welding converters Svarog ARC 205 (J96), Resanta SAI-190, Kemppi Minarc Evo 150, EWM Pico 162, is not at all difficult, using all of the above.

Let's just say one thing - any model that meets the specified requirements will do. For example, German generators of the Fubag and Huter models are suitable for Svarog and Resant, and Endress (Germany) is suitable for Kemppi and EWM.

More details about this assortment can be found in the online hypermarket http://www.tiberis.ru/.

Useful tips for choosing a generator for welding

In order for the power plant and inverter to work efficiently and serve for a long time, it is necessary:

• always select the brand of generator for a specific inverter model based on power and do not forget that it should be overestimated;
• turn on the inverter after the generator reaches a stable operating mode, and turn it off before turning off the generator.

Source: https://steelfactoryrus.com/puskovoy-tok-svarochnogo-invertora/

Resanta 190 sai: description of the welding machine, advantages and disadvantages, recommendations for use - Machine

Reading time: 3 minutes

Resanta SAI 190 is a welding machine from the SAI inverter line, designed for manual arc welding. This model is far from the most budget-friendly of the entire line, but it is not suitable for professional inverter welding. In our opinion, SAI 190 is an inverter for a student welder or a country craftsman.

From this article you will learn everything about SAI 190: technical characteristics, advantages and disadvantages, modifications of this model. And below there is a detailed diagram of the Resanta SAI 190 welding inverter, and more than one.

Characteristics and Features

The inverter welding machine SAI model 190 can be used in conjunction with electrodes with a diameter of up to 5 mm. The maximum welding current that can be squeezed out of this device is 190 Amperes. At least according to the manufacturer???? But practice has shown that achieving such values ​​is almost impossible. The current strength will always be slightly lower than declared.

The welding inverter model SAI 190 has compact dimensions and weighs no more than 5 kg. So you won't have problems transporting it. Summer residents can safely take the device to their apartment for the winter without worrying about its safety. You can cook at temperatures from -10 degrees to +40, which is extremely convenient.

The equipment is modest. The price includes the machine and two welding cables, plus a power cable. All other components must be purchased separately. But you will have access to a 2-year warranty.

Advantages and disadvantages

The first obvious advantage of the Resanta model SAI 190 is its ease of connection. Insert the plug into a household outlet and you can get to work. The main thing is that the voltage in the network is sufficiently stable and is not less than 200V.

The second plus is the “filling” of this inverter. It is designed based on IGBT type transistors. It is thanks to IGBT transistors that the manufacturer managed to make such a compact and lightweight device, which at the same time has additional functionality.

 Resanta welding machine: models for beginners

By the way, about functionality. This inverter welder is protected from overheating and has anti stick (also known as anti-stick) and hot start functions. Your welding work will not only be safe, but also simple.

To use the SAI 190 device you do not need to know the principles of electrical engineering. All controls and buttons are intuitive and labeled in large letters. You will see them even with poor eyesight. Therefore, such an inverter can be given as a gift to an elderly relative or friend who has long wanted to replace the bulky transformer with something more modern.

Now about the cons. The Resanta brand is Latvian, but the production is still Chinese. Two features emerge from this. On the one hand, thanks to Chinese production, the manufacturer was able to set a fairly low price for this model.

On the other hand, not each of us is ready to trust the notorious Chinese quality. Decide for yourself: is Chinese production an advantage or a disadvantage? And share your opinion in x. The second disadvantage is the technical characteristics.

Let's face it, for this price some Chinese brands make inverters that are more powerful and more interesting. Here we overpay for the brand and service.

With such a welder you will not be able to perform professional welding work, and sooner or later you will have to buy something more expensive and more functional.

Circuit and faults

Below we have attached several images with SAI 190 diagrams. Open them in new tabs to view them in full resolution.

And this is a list of the most common malfunctions that occur during operation of the SAI 190. They can be corrected on their own. If more serious damage occurs, we recommend contacting a service center.

Instead of a conclusion

The welding machine model SAI 190 is a good choice for your money. It is suitable for a welding student or an unpretentious summer resident who needs to repair or make something a couple of times a year. The manufacturer also produces various modifications of this model.

Among them are the Resanta SAI 190K inverter welding machine with reduced weight and dimensions for more convenient transportation, the Resanta SAI 190 PN, which operates at reduced voltage in your household electrical network, and SAI 190 PROF for practicing welders.

Choose any one to suit your taste and budget.

Do you want to know which electrodes are best for the Resanta 190 inverter from the SAI line? Read our articles in the “Electrodes” section. We wish you good luck in your work!

Source: https://regionvtormet.ru/instrumenty/resanta-190-sai-opisanie-svarochnogo-apparata-preimushhestva-i-nedostatki-rekomendatsii-po-ispolzovaniyu.html

How to connect a welding inverter

When connecting to a power source and using inverter welding equipment, it is necessary to follow a number of rules that are not only necessary for the safe operation of the device, but can also significantly extend its service life. These rules are suitable for all welding inverters, regardless of type (professional, industrial or household).

Recommendations for the safe operation of the device can be divided into categories:

• sockets and plugs
• wiring
• cables
• voltage and power
• extension cords

In addition, it is necessary to separately consider connecting the welding inverter to the network and to the electric generator.

Network connection

Connecting the welding inverter to the network is possible at a voltage of 220 or 380 V. In this case, it is necessary to take into account a number of external factors and conditions that may affect the service life of the device.

The only elements in the inverter connection diagram that are unlikely to cause problems are the connecting cable and plug. Of course, if they are not damaged. Each manufacturer carefully calculates the maximum power of the device, and the cable and plug can withstand it without problems. Things are a little more complicated with the other elements.

And the first of them is wiring in the room in which welding work is carried out. It is designed for a certain maximum power, upon reaching or exceeding which the protective device is triggered.

The protective device can be either a complex automated unit or an ordinary household plug.

The standard value for most elements of a modern household electrical network is 16 A - this is how much wiring, sockets and plugs can withstand without damage. Therefore, some powerful welding inverters are capable of triggering the protective system when turned on. You should immediately check whether the local network can handle it.

Welding at home with mains power is not always possible

In this case, insufficient voltage should not cause malfunctions in the inverter itself. Such devices are equipped with several levels of protection. Therefore, if the voltage is too low (for example, 190 V), the unit simply will not turn on. The same will happen in the following cases:

1. Wiring cross-section is too small

2. Network overload

3. Faulty fuse

Almost all popular welding inverters work with low-frequency (50 Hz) current, converting it into high-frequency (20-80 kHz).

Connection to an electrical generator

Connection to an electric generator is necessary in the following cases:

• lack of electrical network
• Wiring cross-section is too small (voltage decreases due to resistance)
• Triggering of the protective device when the inverter is turned on
• network overload, power surges
• other options in which connecting the inverter to the network is impossible

The main characteristic that influences the possibility of using a particular electric generator with a specific inverter is power. Moreover, it is necessary to take into account not only the average, but also the maximum power taken with a reserve.

Unfortunately, in most cases, manufacturers do not indicate all the necessary parameters in the technical documentation of the device. But you can calculate the generator power yourself. To do this, you just need to find out the operating current of the inverter.

It is often in the range of 100 to 200 A.

For example, let's take an operating current of 150 A and an arc voltage of 25 V (standard value). We multiply these numbers by each other, take into account the efficiency (on average - 90%), we get 150x25/0.9=4166 W. We also add 25% to this value so that the generator does not have to operate at full power (this can reduce its service life), and we get 4166+4166x0.25=5207 W. This is exactly the kind of generator you will need for an inverter with an operating current of 150 A.

Selecting the connecting cable

Professionals prefer KG as a connecting cable

The connecting cable goes from the inverter to the electrode holder. Most professional welders use KG or KOG1 (a more flexible variety). The KG brand has a cross-section range from 1x16 to 1x95. At the same time, KG 1x16 can withstand loads of up to 189 A, and KG 1x25 – up to 240 A, which is enough for most situations.

Using an extension cord

An extension cord is something that increases the resistance of a wire due to its extra length. As a result, the voltage and current drops. There may be a problem with the direction of the arc. To solve it, you will have to increase the current on the inverter and force it to work at its maximum capabilities. This negatively affects the service life of the product.

Therefore, if possible, it is better to avoid using an extension cord. But there are situations in which this is not possible. In this case, you should be guided by the maximum length of a wire of a certain cross-section at which the voltage will be sufficient for comfortable operation. For example, for an inverter with an operating current of 150 A, a wire with a length of 20 m and a cross-section of 2 square meters. mm will not create problems during operation.  

Source: https://www.Toool.ru/articles/kak-podklyuchit-svarochnyy-invertor.html

Resanta sai 190 cable connection electrodes – Lawyer24

The Resanta SAI machine is designed for electric arc welding. The unit was developed in Latvia, but production is located in China. It is successfully used both at a professional level and for domestic purposes. For welding, they buy piece electrodes with a special coating.

All operation of the device is carried out manually. Resanta SAI 190 single-phase welding inverter is connected to an ordinary network with a voltage of 220 V, at a current frequency of 50 Hz. It is easy to set up and use, which made it possible for the device to gain great popularity among not only specialists with extensive experience, but also amateurs.

Functionality and operating features of the Resanta 190 device

The Resanta SAI welding inverter circuit is based on converting voltage with an alternating current of 50 Hz into a direct component. The constant is then converted back into a high-frequency variable. A pulse width modulator is installed that regulates the welding current.

The welding inverter Resanta SAI 190 is equipped with overheating protection. When it is triggered, a special light on the panel lights up, indicating that the working cables need to be checked for short circuits. Afterwards, work with the device stops.

Without disconnecting it from the network, time is given to cool down.

Resanta is a device that includes the Anti Stick function (protection against electrode sticking) and Hot Start (this allows you to quickly and efficiently start the welding process). Both of these options make the job easier for a beginner. They also increase the quality of the work done, its efficiency and are able to save energy.

Advantageous distinctive features:

1. Increased reliability. The unit has the ability to have a stable and long service life. The inverter welding machine is equipped with a high-quality metal housing that can protect the device from external damage;
2. Convenience over current control. To ensure high-quality seams, the current is adjustable in the range from 10 to 190 A;
3. Easy to transport. A special belt allows you to easily carry the device from place to place.
4. Does not require constant maintenance;
5. High level of productivity;
6. Ability to carry out high-quality welding during network fluctuations. All parameters set for the welding process will not be adjusted against this background.

What is included?

Upon delivery, you receive the Resanta SAI 190 PN inverter itself, a 2-meter cable with an electrical holder, a product passport, a 1.5-meter cable and a grounding terminal.

Peculiarities:

• large depth of the weld pool;
• possibility of gradual change of current indicators;
• power transistors, which are produced taking into account modern technologies, have made it possible to lighten the weight of the device;
• during operation, metal does not splash in large quantities;
• works well during network fluctuations.

Technical characteristics of Resanta 190 PN:

1. Arc voltage - 27 V;
2. Weight - 4.7 kg;
3. Size - 15 x 30 x 37 cm;
4. The value for the maximum current in operation is 25 A;
5. Network voltage - 220 V;
6. Housing protection - lP21;
7. Cooling - air;
8. Electrode diameter - 5 mm;
9. Idling - 80 V;
10. Consumption - 5 kW.

Review of the device Resanta SAI 190 PROF

This model is more popular among professional welders. The principle of operation is similar to the model we have already considered, but there are also some additions in the form of the ARC FORCE function.

It allows you to regulate the change in current strength during the welding process. Before work, the types of metals to be welded and their thickness are taken into account, then the required value is selected from 0 to 100% based on the previously determined welding current.

In this case, the arc will have durability, and the metal will gain fluidity.

Resanta SAIPA 165

Technical indicators:

1. Housing protection - lP21;
2. Adjustable welding current from 10 to 190 A;
3. Arc voltage - 26 V;
4. Electrodes d - 5 mm;
5. Mon — 70%
6. Operating voltage - 100-260 V;
7. Maximum current consumption - 33 A;
8. Idle speed - 65 V;

Advantages of the model

First of all, the modern appearance of the device catches your eye. The control panel has a protective transparent cover made of durable plastic. The digital display will show all values ​​and set indicators for ease of operation. The number of ventilation holes has increased.

There is a special handle on top for easy movement; the unit weighs about 4.8 kg.
All measures taken made it possible to save consumed electricity by 30%. A power factor corrector was installed; it will ensure stability when working with voltages from 100 V.

The device also maintains its functionality when connected to many independent power sources.

Instructions for use of the Resanta SAI 190 inverter

Connecting a device to the network occurs without special rules and requirements. The device is grounded through the plug-in cord, so the outlet must be grounded. The instructions state that for successful connection it is appropriate to install circuit breakers with a value of at least 16 A.

No work should be carried out with tools that create a dusty atmosphere at a close distance from the unit. These include grinders, electric saws or grinders.

If Resanta is operating in normal mode or even idling, you should not cover it, creating restrictions on heat conduction; to ensure stable operation, the cooling system should not be irritated.

Welding is strictly prohibited in the rain or in areas with high humidity. Work with the device does not begin immediately, if it was brought in from the street, where the temperature is currently below freezing, the inverter must stand indoors without operation for at least 2 hours.

Recommendations

Do not turn off the equipment too often; if the indicator lights up, it is appropriate to simply wait a little over 15 minutes until it cools down. When work occurs in intermittent mode for 7-9 minutes, welding does not turn off, you need to wait about 3 minutes of idle operation. A harmless shutdown is only possible if no work is carried out for one hour.

To care for equipment, it is recommended to clean the internal surfaces from possible dust and dirt. The frequency depends on the degree of pollution or the time spent working in dusty areas.

What are the most common causes of device failure?

The first and simple rule that should be followed in order for the welding machine for welding Resanta SAI 190 to serve for a long time and without problems is periodic cleaning and compliance with operating rules, but there are other factors that can lead to repair of the model:

1. Fast heating if the fan fails;
2. An open circuit or cable malfunction will not allow the device to turn on;
3. Due to a cable break, there is no arc, this leads to the burning of the printed circuit board or loss of ground.

Conclusion

Resanta inverters have different pricing policies, ranging from 6,000 to 17,000 rubles. This makes them accessible to every person. All models cope well with household and more complex tasks.

The breakdowns that occurred with devices of this model at first were supported by violations of operating rules, so follow the advice in the instructions to ensure long-term and stable operation of the unit.

Sergey Odintsov

Source: https://jurst24.ru/resanta-sai-190-podkljuchenie-kabelja-jelektrody.html

How to connect a welding inverter to a power source?

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. In order for welding work to take place in the required modes, and for the device to have a long service life, you need to correctly connect the inverter to the power source. Therefore, further we will consider how to properly connect a welding inverter.

Diagram of the device of an inverter welding machine.

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 an external power source, especially if the electrical wiring in the summer cottage is old and has an unknown cross-section.

Modern wiring, plugs and sockets are designed for a current of no more than 16 A. The total power consumed by all devices in the house can be more than this value, so it is limited by an automatic safety device or a regular plug. To connect a welding inverter, you first need to make sure that its input power will not disable the home network protective device.

Welding inverter device.

One of the advantages of this type of welding devices is that their electrical circuit has several types of protection. In case of network overload, the protection automatically turns off the device due to 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 the electrical wiring of a 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.

It is not recommended to connect to the network if a fuse of unknown rating is installed as a protective device.

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.

Also read: All about construction tools from A to Z.

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, the 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. 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?

Connection diagram of the inverter to the battery.

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.

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:

Functionality of the welding inverter.

• length;
• cross-sectional area;
• the value of the voltage drop in the welding circuit.

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 the 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 alternating current circuits with a voltage of no more than 600 V or in direct current circuits with a voltage of no more than 1000 V.

KG brand wires vary in maximum load, depending on the cross-section. The ratio of the maximum load on the cable and its brand is presented in the table:

Cable brand	Permissible load, A
KG 1x16	189
KG 1x25	240
KG 1x35	289
KG 1x50	362
KG 1x70	437
KG 1x95	522

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:

1. Connections should be made using pressed or soldered lugs.
2. 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 are changed.
3. When carrying out welding work, the welder is prohibited from pulling the inverter towards himself with wires.
4. Under no circumstances should the rated power of the cable be exceeded.

Connecting welding inverters using extension cords

Carrying out welding work is often associated with the remote location of the welded structure from the power source. Sometimes in such cases it is necessary to use an extension cord. An extension cord for an inverter is a conductor that has some resistance, which causes a voltage drop in the electrical circuit, that is, the longer the extension cord, the greater the operating voltage drop across it.

If the current is insufficient, the parameters of the welding arc may change and it becomes much more difficult to control. To achieve the required current at the end of the welding cable, you have to set an increased current on the inverter itself, which negatively affects its operation and can lead to failure of the device. Therefore, it will be easier to bring the welding device to the welding site than to buy a new one.

If the situation is hopeless, when choosing an extension cord, you need to be guided by the fact that a cross-section of 2.5 mm2 with a cable length of 20 m when using a device with an operating current of 150 A will be sufficient for normal operation of the welding machine. This length is quite enough for welding at home.

When using a carrier, you should follow some rules:

1. It is forbidden to wind an extension cord onto a reel, since the coiled cable is inductive, which can cause it to overheat and fail.
2. When welding with an extension cord, you need to control the change in mains voltage.
3. Heating of the extension cord is allowed up to a temperature of 70°C.

If you follow all the rules and recommendations when connecting a welding inverter, you will be able to carry out high-quality welding without negative consequences for the device itself.

Source: https://moyakovka.ru/instrumenty/podklyuchenie-svarochnogo-invertora.html

How to choose a cable for a welding machine and what the cross-section should be

Welding is an excellent way to connect parts; it occurs by melting metals using a welding arc. This type of connection is called arc welding.

But to carry out the work you need to know a number of subtleties - polarity, choice of current, electrodes and, finally, the cable itself. The latter is needed to connect the welding inverter to the power source, as well as connect the ground clamp and electrode holder directly to the welder itself.

In this article we will look at how to choose a cable for a welding machine, what should be the cross-section and grade of the conductor.

Cable requirements for a welder

Firstly, if you choose a cable to connect the ground clamp and electrode holder to the welding machine, you need to consider the following operating features:

1. Welding machines of any type produce significant currents - from 10-20 to 400-500A. At the same time, household inverter-type welding machines are usually designed for 200A with a deviation of 50A in each direction, and industrial welding transformers produce currents of 400A.
2. A welder encounters a wide variety of tasks in his work, from simple seams in convenient positions to welding products of complex shapes or in hard-to-reach places.
3. In addition to various tasks, you have to cook both in very hot rooms and in the cold in winter.
4. To transport the equipment, the cables are rolled up.

It follows that the cable must meet the following requirements:

1. The power welding cable must be flexible to ensure ease of manipulation of the electrode or torch for a semi-automatic welding machine.
2. The conductor must have thick insulation and be resistant to aggressive environments, shocks and breaks.
3. To work in cold conditions, the conductor must be frost-resistant.
4. Welding of metals occurs with low voltage but high current, so there is a separate requirement for the cross-section of wires for connecting electrode holders and ground. This means that the wire must be thick to minimize voltage sags and losses.
5. Must withstand repeated bending and winding/unwinding during transportation.

Suitable cable brands and types

The most popular option for a welding machine is the KG cable; it is a flexible single-core cable with a stranded core in rubber insulation. COG is also popular - with increased flexibility. There is also a specialized KS, these are the main brands of conductors that are used for welding work.

The title may also contain a note about the performance:

• T – tropical version, can operate at ambient temperatures up to +50 (according to some sources 85) degrees Celsius.
• KX or HL - frost-resistant, works even at -60 degrees Celsius.

And also the prefix P - an additional sheath of the core made of polymer materials.

The numbers in the marking indicate the number of cores and their cross-section, for example: KG 1x16 indicates that it consists of 1 core with a cross-sectional area of ​​16 square meters. mm.

Selection of section and length

The cable cross-section for the welding machine is selected based on the current. For a rough estimate of the required cross-section, we have prepared a table:

Section, sq. mm	Current, A
1x6	80-100
1x10	120
1x16	189
1x25	240
1x35	289
1x50	362
1x70	437
1x95	522

The length of the cable is a subject of debate among many craftsmen. As the length increases, while the cross-section remains unchanged, its resistance, as well as inductance, increases. If you choose a cable that is too long, you will not have to wind it into a reel when welding near the welding machine, but if you choose a short one, you will have to constantly move the welder.

On the other hand, if you do not weld large volumes in production, then the optimal length of the welding cable will be 5-10 meters, and connect the machine to the network via an extension cord. Moreover, amateur inverter-type devices, which have been used more often than others lately, are quite compact and lightweight, so carrying them will not cause any particular difficulties.

If you still need to extend the existing wire, sleeves are best suited.

Cable for connecting the welder to the network

In addition to connecting the electrode and ground to the welding machine, you also need a cable to connect the welder to the power supply. Regardless of what type of machine, inverter or transformer, the welding current reaches hundreds of amperes, but the supply current is much lower. It can reach about 30-50 Amps, depending on the power of the welder.

Therefore, to power it you do not need such a thick cable as for the electrode holder. It is calculated depending on the distance from the connection point to the power grid. If you have a single-phase household appliance of the inverter type at 220, or a two-phase transformer at 380V, then a copper conductor with a conductor cross-section of 2.5-4 kV, mm is suitable. Based on the number of cores, a two-core cable is used if there is no grounding at the site and a three-core cable if you are connecting to a grounded outlet.

For convenience, a network cable 3-5 meters long is enough, and for carrying around the site, use a carrier with a cross-section of 2.5 square meters. mm, if the carrying length is 10-20m. For reliable operation of the device from a longer carrying distance, for example 40-60 meters, it is better to take a cable with a cross-section of 4 square meters. mm.

If you are going to use a long carrier, it is better to buy an extension cord with a reel, then the cable will not get tangled under your feet and will last longer. However, in the coil it will not be cooled well, so that it does not overheat, it is better to take a cross-section with a margin.

For industrial three-phase 380V devices, four-core copper cables with a cross-section of 4-6 square meters are used. mm, or aluminum - with a cross-section from 16 sq. mm. Do not forget to check the correct connection and direction of rotation of the cooling fan, if present.

Operating rules

Instead of a conclusion, we’ll tell you how to choose and operate a welding cable correctly:

1. You need to connect the wires to the welding machine using cable lugs; they are crimped or soldered.
2. To extend and join several sections, sleeves or a connection method other than twisting are used.
3. In welding inverters, the wires are usually connected using bayonet connectors. This must be taken into account and purchased in advance, otherwise you will not be able to use the cable with such a welding machine. With their help, you can quickly change the polarity of the current.
4. Don't buy wires that are too long or gauge unless you intend to use it to its full potential. This will lead to excess conductor mass and operational difficulties.
5. Do not pull the welder closer to you by the cables to avoid damaging them.
6. Do not exceed the permissible current through the wires.
7. An extension cord with a reel will become indispensable when the welder frequently moves around the site.

Source: https://samelectrik.ru/kak-vybrat-kabel-dlya-svarochnogo-apparata.html