How to properly connect inverter welding

How to connect a welding machine

Before welding, at a minimum, you need to understand how the welding machine is connected to the existing network, as well as what conditions must be observed.

To quickly and efficiently connect the welding machine, you should follow the current operating instructions for devices of this class.

Of greatest interest from the point of view of the features of this process is the connection of a welding inverter, most often used at home.

Safety regulations

The connection diagram for an inverter welding machine is quite simple and allows the device to operate in a cyclic (intermittent) mode, which allows for maximum welding efficiency. Before plugging into a socket, you still need to read the connection instructions, check the network parameters, completeness of the equipment and the external integrity of all its parts .

Options for connecting the inverter to the network

The instructions should clearly describe how to properly connect the welding machine, and also stipulate the procedure for its safe connection to the current electrical network. The need to check plugs and circuit breakers installed in the power supply circuit is specifically stated.

The fact that in old houses aluminum wiring does not allow working with currents above 10 Amperes should also be taken into account. Therefore, before connecting converters to the network, it is necessary to find out their rated power and current consumption.

When assessing the power taken from the network, one should not forget that when the device is turned on, there is a sharp surge in the starting current, the value of which can exceed the rated value several times.

Before connecting the device and welding work, the operator must fulfill the following requirements of the operating instructions:

1. remove foreign electrical devices (computers, transmitters, measuring instruments) from the device body;
2. when working with inverter equipment, the workplace must be cleared of all other interfering objects;
3. The rooms in which the welding unit is located must be equipped with a forced ventilation system.

To avoid emergency situations, before connecting the welding machine for the first time, it is recommended to test it in various welding modes.

Turning on the device (operating instructions)

When considering the operating conditions of a welding inverter, first of all, you need to pay attention to the following points:

• the normal duration of the current load should not exceed 5 minutes;
• in practice, the so-called “three-minute cycle” is usually used, which is two-thirds of the full load;
• If strong heating of the case is detected, the device must be turned off until the causes of the overload are determined.

Welding using an inverter machine requires careful preparation, since dangerous situations are possible when working with equipment of this class. Before starting welding work, the operator must fulfill all the requirements of the operating instructions, including choosing the appropriate current mode and electrode type .

Connecting the inverter to the network and putting it into operation is allowed only after meeting safety conditions, including the use of sockets and plugs of the appropriate standard.

When operating a welding machine, you should use special coated electrodes (MMA type).

The thickness of MMA electrodes is selected based on the mode and type of metal to be worked with. Typically, the thicker the metal, the greater the current required and, accordingly, the diameter. The most common ones used at home are 2 and 3 mm electrodes.

Before starting welding, make sure that the electrodes are dry. The wire going to the torch is connected to the minus terminal, after which the gas hose is connected to the reducer located on the cylinder if welding is performed in a protective environment.

When connecting via an extension cord, you need to pay attention to the cross-sectional diameter of its cable. The cross-section must be at least 1.5 square meters. mm for working with current up to 16 A. The wire must be completely untwisted so that there is no inductance, which, after connecting the welding machine, will create additional resistance.

Launch Mode Features

The inverter is put into operation by pressing the “Start” button, which leads to a state of complete readiness for welding procedures. To start welding in a protective gas environment after connection, just slightly unscrew the torch valve, install the desired electrode and “strike” it on the workpiece to be welded.

When considering starting an inverter, the following must also be considered. The fact is that any inverter device is equipped with a soft start device that prevents the failure of the electronic elements of the circuit from a surge of current.

Despite such protection, current surges when turned on can reach values ​​of the order of 40 Amperes, which are dangerous not only for the outlet, but also for the existing electrical network due to the strong “sag” of voltage.

During current surges within the above limits, the mains voltage may decrease (“sag”) from 220 to 130-140 Volts.

It is recommended to connect the power supply circuit of the device to the terminal contacts located directly on the distribution panel, where the grounding bus is also supplied separately. For a machine installed in an input device, such voltage drops are less dangerous.

The situation with inrush currents is significantly simplified when linear rather than phase voltages are used to power the inverter. However, this option can be implemented only for devices designed for 380 Volts and provided that the house is connected to a three-phase network (generator).

When considering the features of putting an inverter device into operation, one should not forget the features of adjusting its load current, which is carried out automatically (using a special control unit). Setting elements that set the control limits are located on the front panel of the device.

Compliance with the instructions for connecting pulse converters is mandatory for all models of welding devices without exception. Only if the starting conditions for inverters are met is it possible to maintain their functionality and guarantee high efficiency of the welding process.

Source: https://svaring.com/welding/apparaty/podkljuchenie-svarochnogo-apparata

How to weld metal correctly with an inverter for beginners

Specialized equipment is used to connect blanks and sheets. The most popular are inverter type devices. To make a high-quality weld, beginners need to know how to properly weld metal with an inverter.

What is a welding inverter and how does it work

An inverter is a modern piece of equipment that is used to connect metal parts. The principle of welding with an inverter is similar to other welding machines. The device produces a current of maximum strength, due to which an electric arc appears.

Subsequently, it is maintained due to powerful voltage and allows the metal to be heated. In the case of an inverter, an arc appears between the surface being processed and the electrode. Its difference is that in standard models, powerful voltage is generated using a transformer.

The inverter has a different system.

To create a powerful voltage, the 220V input current passes through a special rectifier. There it is converted into a permanent one. Next, the direct current is converted into alternating current with a frequency of up to 100 kHz. At the last stage, the flow is straightened and subsequently used in welding work. It is important to know how to weld pieces together and what is needed to achieve a strong structure.

Design and advantages of inverter welding machines

Before buying inverter-type welding equipment, it is advisable to familiarize yourself with its structure and strengths.

The inverter design consists of 4 key parts:

1. Transformer. In inverter-type models, this element is no larger in size than a cigarette pack. It is designed to reduce high frequency alternating voltage.
2. High frequency rectifier. This element equalizes the alternating current coming from the general network. After it, the current enters the high-frequency filter and exits in a constant flow.
3. Filter. It consists of a capacitor and a choke. Designed to smooth out rectified current.
4. Rectifier. A diode that receives the initial current flow from the general network.

All elements are placed in a metal or plastic case on which the device control system is located.

Inverter advantages:

1. The efficiency of such devices can reach 90%. Almost all the energy that the equipment consumes goes to creating and maintaining the arc.
2. Power consumption is lower than models with a larger transformer.
3. Small dimensions. Low weight. Thanks to this, the welding machine can be used in hard-to-reach places.
4. Minimum amount of molten metal splashes during operation.
5. Minimum load level on the general electrical system.
6. Possibility to select electrodes of the required characteristics.

The inverter is easy to work with. For a person without experience, it is enough to try welding parts together 2-3 times in order to understand how to make a seam correctly.

Inverter welding machine

Preparing for work

Before welding metal with an inverter, you need to prepare a workplace, electrodes, and equipment. To learn how to weld using electric welding, you don’t need to look for professional tools and workbenches. A small metal table is a good place to start. The main thing is that all the tools, welding machine and workpieces can be freely placed on it.

It is important to prepare high-quality lighting and ventilation in the room. When welding metals, harmful fumes are released. In addition to lighting and ventilation, it is necessary to remove flammable materials and liquids as far as possible. The welder needs to stand on a material that does not conduct electricity.

Electrodes are selected depending on what metals need to be welded and how thick they are. The packaging of consumables indicates what material they are intended for.

After selecting the electrodes and preparing the workplace, you need to connect the equipment. There are two cables coming out of the inverter. One is a mass and has a "metal alligator" at the end. It is attached to the workpiece or to a metal table. The second cable represents the clamp for the electrode.

Working as an inverter

Before turning on the device, it is advisable to familiarize yourself with how to cook using inverter welding. Instructions are included with the purchased equipment. The main stages of the work will be described below.

Ignition of the arc

First of all, you need to ignite the arc. Two methods are used for this:

1. Strike - the welder begins to move the electrode along the workpiece being processed, and then rises above it until a spark is formed.
2. Tapping is a more popular option for igniting an arc. The welder taps the end of the electrode on the site of future welding until a spark appears.

The method of igniting the arc is selected depending on comfort and convenience.

Electrode movement

To properly weld part to part, you need to know how to move the electrode. Beginners think that it is enough to light an arc and slowly move the electrode over the contact point of the parts to get an even seam. It is important to correctly select the constant angle of movement of the electrode and the speed of movement of the working part of the equipment. Driving the electrode straight at a right angle is acceptable for thin sheet metal.

Arc gap control

Another important point when welding with an inverter is the distance between the end of the electrode and the metal surface. If the distance is about 2 mm, the welding will be shallow and the seam will not be strong. When the arc is larger than 4mm, it becomes unstable. Metal spatter increases and weld accuracy decreases. It is advisable to place the working part of the inverter apparatus at a distance of 3 mm from the metal surface.

Rules for creating smooth seams

To properly weld metal and make smooth seams, you need to take into account some features:

1. Selecting the welding angle. The optimal range of angles is from 30 to 40 degrees.
2. Laying the seam requires longitudinal and transverse movements. There are various schemes on the Internet by which you can train the movements of applying a seam.

The speed is selected depending on the chosen method of working with the electrode. If you move the electrode slowly, you can overheat the surface. When done quickly, the seam is not strong.

Equipment and safety

You can carry out not only welding, but also metal cutting with a welding inverter. When carrying out work with welding equipment, it is necessary to take into account the safety rules:

1. The equipment must be checked for defects and breakdowns.
2. The welding process is harmful to health. To protect your eyes, you need to use a special welder's mask. It is equipped with light filters that protect your eyesight.
3. In addition to the mask, the welder needs protective gloves, overalls, and shoes.

The place in which the welder works must be equipped with a special curtain that protects the vision of strangers.
WELDING INVERTER.
WELDING TECHNOLOGY When using an inverter, it is necessary to take into account the design of the equipment, know the methods of guiding the electrode, and correctly select the angle and speed of guiding the working part. We must not forget about safety precautions and workplace preparation.

Source: https://metalloy.ru/obrabotka/svarka/invertorom

Inverter welding for beginners: basic rules and tips

When we mention the word “welding,” we immediately imagine a complex process with many nuances, rules, difficult-to-use machinery and equipment, and requirements for the worker’s skill level. But this is not always the case. Modernity, with all its technical innovations, does everything to make human life as easy as possible. It did not bypass the welding process either.

It turns out that you can know how to weld using inverter welding yourself, without special qualifications and skills in using complex welding equipment, and welding with an inverter for beginners will not seem so difficult. All you need is to purchase an inverter for welding and follow the rules on how to learn to weld with inverter welding.

Inverter Welding Basics for Beginners and Inverter Welding Lessons for Beginners are given below.

What is an "inverter"?

Inverter welding technology implies the mandatory use of this device for work. At its essence, an inverter is a device that converts alternating current from our regular 220 V outlet into direct current, while changing the frequency.

Another plus is that such a serious device uses your electricity very economically and does not noticeably change the voltage reading. There are inverter devices that operate at a voltage of 380 V. Welding with a three-millimeter electrode will be possible at a voltage of 170 V.

But it is better to check this in the operating instructions for a specific type of inverter. Such low voltage is usually typical for villages and small towns.

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

Visually, the device is a metal box, with indicators of some indicators: overheating and power supply, sometimes there are grilles for better cooling of the contents, with a strap for easy carrying and a handle. Weight approximately 3-6 kg.

The inverter has a knob that regulates the welding current, two holes for cables - plus and minus. One is used as a clothespin for the part, the second is used for the electrode holder. It is recommended to purchase an inverter with cables of the correct size. Sometimes they are too short.

Also, cables should be as flexible as possible for convenience.

How to choose a welding inverter? Quite simple. Prices for inverters are quite affordable. But there is a price range. Buying the most expensive one is not the best option for a person just learning the basics of welding with an inverter. Working with a welding inverter manufactured by Resanta is convenient and productive.

When answering questions about how to use a welding inverter, how to properly weld with a welding inverter, and how to learn to weld with a welding inverter, first of all, you need to say the following.

Before welding correctly with inverter welding equipment, be sure to carefully read how to weld with a welding inverter from a specific manufacturer. Possible several times.

The principle of operation of inverters is the same, but in other indicators there are many differences that cannot be outlined in any universal welding manual.

How to weld parts? Basic techniques and secrets for beginners.

Any welder knows how to weld with a welding inverter. Inverter welding is based on a completely classical principle. The metal is welded by an inverter from the high temperature of the electric arc. In order for an arc to appear between the electrode and the metal part, they must be connected to different poles.

The choice of plus or minus for the electrode and metal depends on the thickness of the part to be welded. There is a division into direct and reverse polarity or electrode-negative and electrode-positive. The last name for the varieties of polarity is more understandable.

With direct or electrode-negative polarity, the welding electrode is connected to the minus, and the metal part to be welded is connected to the plus. If you swap them, the polarity will be reversed or the electrode will be positive.

There is a difference between these two types of connections. The welding electrode or welding part will heat up more if a positive charge is attached to it. This happens because the electrodes in the arc move from minus to plus, which makes the temperature of the plus higher.

When welding pipes thicker than 3 mm, it would be more advisable to connect a positive charge to the pipe. Pipes of this thickness need to be significantly “warmed up” to obtain a good seam. Therefore, by attaching a plus to the pipe, the metal will melt better, the seam will be of high quality and durable.

If the pipe is made of thin metal, then a positive charge can “burn” it, thereby rendering it unusable. Therefore, it is better to connect a minus to it.

What is a weld and how to make it?

A weld seam is a section of a welded joint formed as a result of crystallization of molten metal. The welding electrode is a metal rod, a core, which is covered with a special coating that prevents oxygen from entering the welding area (welding pool). The rod is made from conductive metals so that the electric current flows directly to the part being welded.

The process of creating an electric arc is the connection of a metal electrode rod with a product. The special coating around the electrode rod begins to burn and melts. When the coating melts, gases are released that surround the weld pool, protecting the metal from oxygen during the welding process. The molten coating next layer protects the newly molten metal from oxygen after welding. This layer of molten coating is called slag.

The process of joining metal itself has even more nuances. To obtain a high-quality seam, the two pieces of metal being welded must be heated to the same temperature. The metal must be molten at the same distance from the edge of both products. Since the electrode is consumable, during welding its particles “displace” the arc closer to the seam, so you need to constantly move the holder closer to the workpiece.

To make the seam wider, you need to “draw” various types of patterns with it during the welding process: circles, zigzags and others. Learning to do this the first time will still not be easy, even though the welding inverter’s arc does not “jump.”

Electrode movements when welding with an inverter

Where to start welding metal with an inverter?

How to use a welding inverter? First you need to take care of safety. To weld, you need to purchase a mask, closed boots and gloves made of thick leather, and thick clothing. Your uniform should protect you from sparks. In addition to personal protective equipment, you need to take care of the safety of people and objects around you.

If you are going to “cook” at home or in other places where people may appear without special protection, you should warn them about this. If this does happen, stop welding immediately. Clear the area around the welding site of unnecessary objects, flammable items and liquids that could cause a fire or explosion. The work must be performed on a special wooden flooring in order to eliminate the possibility of electric shock.

Make sure you have a bucket of sand nearby. Proper operation of welding equipment equals safe operation.

The metal you are going to “cook” must be prepared. It must be cleaned of excess: rust, paint. The edges must be treated with solvent. There should be no traces of grease or paint on them.

Next, we connect the welding cables where necessary, select the desired electrode, and set the current value. The table below shows how to select the right electrode. The diameter of the electrode depends on the thickness of the product to be welded. Recommended values ​​are given.

Metal thickness, mm	2	3	4-5	6-8	9-10
Electrode diameter, mm	2	3	3-4	4	4-5
Welding current, A	50-60	110-120	110-120 (at d=3MM) 140-160 (at d=4MM)	140-160	140-160 (at d=4MM) 225-300 (at d=5MM)

How to use a welding inverter?

Do not hurry! If you rush to make a seam, you will most likely end up with a poor-quality connection.

During the welding process, the current value can and should be changed if required. If you see that when creating a seam you get not rollers, but something like blurry lines, then you should increase the current. If the rollers are so huge that it becomes difficult to move the electrode holder, we reduce the current indicator.

If you are using not just purchased electrodes, but those that have been stored for some time in damp places, then they need to be dried for about two to three hours at a temperature of approximately 2000 degrees.

There are two ways to ignite an arc:

- strike the tip of the electrode against the product several times;

-use a method similar to lighting a match.

To get the hang of making a seam, you can first mark the intended line on the metal. Mark it so that you can clearly see it. Next, we ignite the arc and direct it to the mark all the way. There the metal begins to melt and the whole thing is covered with slag, as mentioned above. This is the weld pool; it needs to be moved, “drawing” patterns, as shown in the figure above.

You need to move the weld pool with the electrode at a certain angle. There are two differences in how to weld parts: at an angle forward and at an angle back. The first type allows you to cook with less heat, which is great for thin metals. Accordingly, the second type of welding is typical for thick metals.

In addition to all the above indicators, the optimal length of the welding arc should also be observed. This is the distance from the end of the electrode to the part. There is short, medium and long. Short – 1 mm, medium – 2-3 mm, long – 5 mm or more, until the arch completely separates and disappears.

For a beginner, the optimal length is considered to be a medium arc. With a long arc, the metal does not heat up enough because it “jumps”, the weld will not be of good quality. When welding with a short arc, beads that are too convex appear, there is little heating near them, this can lead to the appearance of undercuts (grooves along the seam).

This also makes the seam of poor quality.

If the seam turns out to be defective, don’t be upset, you can still correct it. To do this, you need to remove the area of ​​the poor-quality seam and “weld” it again. Or “patch up” this area.

Welding with an inverter for beginners on thin metal is characterized by the presence of the main types: butt and overlap. For beginners, it is easier to overlap weld; there is a guarantee that you will not weld the metal to the table. Butt welding of thin metal has many difficulties and features when using an inverter. More often, semi-automatic welding machines are used for this, which no one usually buys for themselves. Using an inverter welding machine for beginners is usually risky.

So, this is the basic information, tutorial and rules that you need to know and follow if you decide to learn how to weld metal with a welding inverter. Welding for beginners, of course, is characterized by initial failures. Initially, you will need to learn how to perform each stage of work several times to bring it to the proper level.

You will have to train, use a lot of “test” electrodes, pieces of metal, learn how to light an arc well and the first time. But, you see, this is a small price to pay for the opportunity to learn how to learn how to properly weld with a welding inverter yourself from scratch and save on the services of specialized companies. The inverter welding technique is quite transparent and simple.

Having gone through all the trial stages and learned the lessons on welding with an inverter for beginners, you will be able to weld on your own without any problems.

Source: https://svarkaed.ru/svarka/obuchenie-svarke/invertornaya-svarka-dlya-nachinayushhih.html

How to quickly learn to weld with a welding inverter

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.

Other accessories:

• 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:

• tapping;
• chirping.

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.

Seams are divided into:

• 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.

The polarity is indicated on the pack of electrodes; these instructions will help you correctly connect the wires to the equipment.

Welding thin metal with an inverter

The essence of connecting thin plates comes down to selecting small-diameter electrodes and adjusting the welding current. For example, for metal with a thickness of 0.8 mm, electrodes with a diameter of 1.8 mm are used. The current on the inverter is set to 35 A.

Technology occurs in intermittent movements. Watch a video showing how to join thin plates in detail.

How to cut metal with a welding inverter

To properly burn a hole in a pipe, we set the current on the device to 140 A for a 2.5 mm electrode. We light the electrode, placing it in one place to warm up the metal and press it in. We move the electrode to a new place, warm it up and press it in. Gradually, we cut a hole in the pipe.

Pipe cutting

When cutting, it is better to place the plate vertically so that the molten snot flows down. If you cut in a horizontal position, icicles will harden at the bottom of the cut. That's all the tricks!

Beginners are tormented by the question, which polarity of wires is better when cutting with an inverter?

1. When cutting with electric welding, straight polarity is preferable. The melting zone is narrow but deep.
2. With reverse polarity, the melting zone is wide but shallow.

It is not recommended to cut with electric welding (metal melts from the cut zone). It’s better to take a grinder and cut off the desired piece.

Source: https://plavitmetall.ru/svarka/invertorom-dlya-nachinayushhix.html

How to properly weld with inverter welding for beginners: alternating and direct current, cable cross-section

If you are going to do welding work yourself and decide to do it using an inverter machine, you need to understand in advance how to work with a welding inverter.

Then read this article: everything written here will be useful to you.

Preparing, purchasing, stocking up

The most important thing is to know that everything will work out perfectly, because inverter welding technology is very easy to learn and use; experience and skill are not particularly needed here.

Safety precautions

Any welding activity, including an inverter, is directly related to electrical current.

These rules are simple and straightforward:

• It is necessary to check the cables for integrity and serviceability before connecting to the inverter. It is important to remember: the return cable with a clothespin goes to the negative pole. We attach the cable, where there is an electrical holder, to the positive connector.
• After a visual check, set the current control knob to the minimum value. Then we connect the device to the network. We listen to the operation of the fan when it turns on: if the noise is smooth and without crackling, everything is in order.
• Now let's take into account the considerable weight of the metal with which you will have to work.

Workwear

First of all, you need to take into account the effect of high temperature and have the following items:

• welder's mask with special light filters;
• protective gloves or gaiter;
• suit made of protective fabric;
• shoes with rubber soles;
• if necessary, a respirator if welding takes place in a closed room without ventilation.

Equipment

List of required equipment:

• inverter welding machine;
• hammer;
• electrodes selected for the type of work, taking into account the nature and thickness of the metal;
• metal bristle brush

Let's start cooking

First we set the correct current strength on the inverter. We remember that in inverter technologies, alternating current welding is the main type. The strength of the welding current depends on the composition of the electrode and the diameter of its tip, the position of the workpieces during welding and the type of seam in the planned joint.

All these dependencies can be found in the comprehensive instructions for the device itself and in the inserts in packs of electrodes. Theoretically, the welding current can be selected according to the diameter of the electrode rod: for each millimeter of diameter there should be about 30 A.

We find a comfortable and stable position, put on a mask and begin work with the elbow abducted. It is better to wrap the forearm with a cable. If this is not done, your hand may get tired during welding, and the cable will begin to dangle, which will negatively affect the quality of the weld.

Direction of electrode movement for a novice welder.

For debut work, it is better to choose metal blanks that are not the smallest size - more than 20 cm, this will be more convenient. As beginners usually do: put on a mask, ignite an electric arc and immediately, with one breath, pass the workpiece along the entire length of the seam.

If your part is short and you weld it in one breath, you may develop the unnecessary habit of welding the seam in one breath. Therefore, train on long parts with proper breathing.

Now about the arrangement of objects during work. It is better to place the workpieces on a work table - a horizontal surface. The electrode in the holder should be at right angles to the table plane, then the angle of inclination should be approximately 30°.

Now you need to ignite the arc to move along the planned weld.

It must be remembered that when burning, the electrode shortens, so the distance above the surface must be constantly monitored.

Now about the arc and electrodes

Quickly igniting and holding the arc correctly is perhaps the most important thing for successful welding with an inverter. The arc should not be interrupted - this is what you need to watch out for when the electrode approaches the workpiece plane.

In this case, you should tap the electrodes longer so that the film breaks. The relationship between welding current and electrode diameter can be easily calculated using tables that are available in large numbers on the Internet.

Functional diagram of welding with an inverter.

If you have an advanced inverter model, then it is equipped with additional functions that make life easier for beginners and everyone else.

These advanced features are:

• The Hot Start or HotStart function makes it easier to ignite the electric arc.
• Anti-sticking or arc forcing is activated when the electrode approaches the metal surface too quickly. This function increases the current level.
• Antistick or AntiStick, on the contrary, turns off the current to prevent overheating of the welding machine.

It is better to learn from the simplest form of seam - a thread seam, for which the electrode must be guided evenly without any oscillatory movements.

Once you start to feel comfortable with the thread technology, you can start welding metals with oscillating movements in different configurations - there are several of them.

In such cases, you need to make the first few oscillatory movements to form a weld pool. We tilt the electrode at an angle of 30°, no more and no less. Once the pass is completed, you need to beat off the slag crust with a hammer to clean the new seam using a wire brush.

In order for the seam to come out high-quality and aesthetically pleasing, at the end you should make a couple of oscillatory movements towards the metal surfacing. In this way, crater formation can be avoided.

About welding seams

The seams that are formed using inverter welding are as follows:

• single-pass, in which the thickness of the metal workpiece is replenished in one pass;
• multi-pass, in which one pass of electrodes is not enough. Used when welding thick edges.

The most famous and simple way to check the quality of a seam after welding is to tap it with a hammer. At the same time, the slag layer bounces off - provided that the seam is even and smooth. Also, the quality of the seam depends on the temperature: it must be correct.

If the seam is overheated, it may break; if the heating is insufficient, a very unpleasant thing will happen - lack of penetration.

Polarity forward and reverse: what is the difference

Polarity in welding on an inverter machine is an extremely important thing that you need to understand.

At its core, polarity is the direction of electron flow, which depends on the order in which the cables are connected to two different connectors on the device. Inverters have the ability to select the type of polarity. The welding current can also be adjusted.

Reverse polarity

Types of polarity for welding.

This is the negative pole on the metal workpiece, and the positive pole on the electrode. The current thus moves from minus to plus, that is, from the metal to the electrode. With this method, the electrode gets quite hot. The method is good when welding thin metals as the risk of burn-through is reduced.

Straight polarity

Here it’s the other way around: the negative pole is on the electrode, and the positive pole is on the metal of the workpiece. The current now flows from the electrode to the part being welded, which in this case heats up more than the electrode. This is how they work with thick metal edges.

It should be noted that the polarity is always indicated in the instructions on the packs of electrodes.

One of the main “inverter” questions from debutants is what is the most optimal polarity when welding with an inverter? The answer depends on many criteria, but from the point of view of cutting metal, the polarity should be straight.

The fact is that with this type of polarity, the molten area turns out to be deep and narrow - just what is needed when cutting.

With reverse polarity, the opposite is true: the melting zone is shallow and quite wide.

Cook, cut

If you are working with thin sheets of metal, you need to choose the right small diameter electrode and welding current. If, for example, the edge thickness of your part is 0.8 mm, the diameter of the electrodes should be 1.8 mm. Well, the welding current should reach 35 A. You need to cook using intermittent movements.

The question of which electrodes to weld with is decided taking into account the type of welding and the nature of the metal.

We ignite the electrode and place it exactly at the location of the planned hole. Press for good heating. We rearrange the electrode, press and heat again. And so on until a hole of the desired shape and size is cut.

If you are cutting sheet metal, the sheet must be fixed vertically. In this case, drops of molten metal will flow down, otherwise you risk getting frozen metal icicles at the bottom of the cut.

To be honest, all cutting of metals with a welding machine, even with the most advanced inverter, is not the best idea from a technical point of view. There is always a risk of metal melting at the cut site - the metal can simply melt out. The best way to cut metal is with a grinder.

We choose, we buy

Table of characteristics for welding with an inverter.

It would be useful to google and read about domestic and foreign manufacturers whose products are offered on the Russian market. These are mainly European and Asian countries.

Equipment from Asia is usually inexpensive and of very decent quality, with the exception, of course, of handicraft fakes.

European inverters are distinguished by qualities with the obligatory adjective “high” in front: high price, high reliability, high quality. There are few Russian devices on the market.

Understand the brand of welding cable and its cross-sectional area. The right choice will help you avoid difficulties with power surges if they occur during welding.

The second thing to do is figure out the availability of service centers around the country. If you live in a city with a population of one million, a service center for a specific product is unlikely to be a problem for you. But if you live in a remote region, this issue will become one of the most important for you.

But the main thing is protection from ultraviolet radiation from a hot arc. The most primitive option is a mask made of plastic and a light filter, which is selected depending on the current strength, lighting and your vision.

A more expensive and much more comfortable option is a mask with a Chameleon-type light filter, which automatically changes its characteristics and can be adjusted to suit the ambient light and the condition of your eyes.

There are many tables on the Internet with data that will help you choose the right filters. It is better to choose them for a number larger or smaller. The best solution would be to check the lighting in the work area and your vision.

Okay, we agree, you don’t have to buy a whole suit made of special fabric. But a canvas apron with gloves is not a whim, but your protection. It is better to choose mittens from split leather. Pay attention to your shoes: be aware that drops of molten metal may fall on your feet.

How to care for the inverter?

Any equipment loves care and order, your inverter is by no means an exception. The rules on how to properly cook using inverter welding and how to store it correctly are simple.

Selecting an electrode for welding various metals.

Before work you need to do the following:

• carry out a visual inspection of the device and prepare the place where you are going to work;
• install the inverter in a horizontal position with the desired protection from dust, precipitation and other contaminants;
• connect the cable to the connectors in accordance with your plans, usually this is plus to the electrode and minus to the metal;
• connect power supply. The most important nuance: if you use an extension cord, the cross-section of the welding cable must be at least 2.5 mm².
• ignite the arc at separation as a test test;
• make sure the casing is intact, because cooking without it is strictly prohibited;
• adjust the current mode. You can start cooking.

You must store your device according to the following rules:

• Constantly check all components of the device. The frequency of checks depends on the intensity of use of the device and the degree of dust in the work area;
• Clean the device from dust using compressed air and low pressure. Do not clean the electric plateau with a jet of air, but use a soft brush;
• check the strength of power connectors, the integrity of the plug, socket and insulating coating of electrical cables;
• It is better to store the inverter in dry conditions, the air temperature should be within the range from -15°C to +50°C, the optimal air humidity is about 70 - 80%.
• Remember to disconnect the inverter from the network when it is not working.

Source: https://tutsvarka.ru/vidy/kak-pravilno-varit-invertornoj-svarkoj

How to connect welding cables to each other, connect to an inverter, clamp in a holder, extend, etc.

Quite often, welders have problems connecting cables . This question may arise for several reasons: the wire that comes with the welding machine is not long enough, or the cord was broken or damaged during work. Therefore, it is important for performers to know how to properly connect welding cables and extend them.

How to connect

It should be remembered that the safety of the performer and the quality of the work performed depend on the reliability of the contact connections of the conductors. The connections are subject to high technical requirements . But first of all, they must be resistant to shocks, tears and other mechanical influences. Therefore, it is very important to know how to connect two welding cables to each other.

The following are the most popular methods of connecting welding cables, each of which has its own advantages and disadvantages.

Let's look at the connection of welding cables in more detail.

1. The simplest way is to use additional accessories - welding connectors for connecting cables . They make work simple, fast and convenient. In addition, the use of connectors has a positive effect on equipment mobility.

There is a wide variety of these accessories on the market, differing in technical characteristics. Connection of welding cables: “male-female” - is a classification based on differences in the design of the connectors. You can find out how to choose the right detachable connections for welding cables and what you should pay attention to here.

2. The “twist” connection is the first and oldest method, characterized by fairly simple execution, quality and reliability.

Main disadvantages : this method is prohibited by a group of regulatory documents PUE (“Rules for the construction of electrical installations”); is an intermediate step before welding or soldering.

The prohibition of the PUE method does not prevent homemade workers from successfully using it, as shown in the video below.

“Twisting” can be done in several ways, which are presented in the pictures below. Regardless of the chosen method, the insulation of the cores should be removed by at least 3-4 cm. Then the sections of the cores must be treated with acetone or white spirit, cleaned with sandpaper and you can begin twisting.

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There are also ways to connect welding cables if you have a certain set of equipment and additional accessories.

3. Soldering is a method of connecting cables by covering the heated ends of the wires with molten solder, which hardens and provides strength and high electrical conductivity of the connection. This method is used for small cross-section conductors.

Advantages: does not require special skills and specialized equipment compared to welding.

However, it is worth highlighting the disadvantages: a large number of preparatory operations, therefore, high labor intensity.

Before soldering, the conductors are cleaned of insulation and oxide film, then they are tinned, twisted and pressed with pliers. To avoid oxidation of the cleaned surface, fluxes should be applied to the treated areas.

Soldering of small copper wires is carried out using solder tubes filled with rosin or a solution of rosin and alcohol. These solutions are applied to the joint before soldering.

Then you can begin the soldering process: the joint is heated with a soldering iron or torch. Rosin or flux begins to boil, take a little solder onto the soldering iron tip and add it to the soldering zone by pressing the tip against the conductors. The solder spreads and fills the gaps between the wires, thereby creating a connection. If a torch is used, the solder is added to the torch.

After the soldering process is completed and the workplace has cooled, the flux residues must be washed off, the joint dried, coated with a special varnish, and insulated with tape or heat-shrinkable tubing.

4. Crimping is the process of connecting wires using copper or aluminum sleeves. It is necessary to select a sleeve depending on the size of the “twist” and the cable material (copper or aluminum).

The wires must be cleaned to a metallic shine, bundled/twisted, and then a sleeve is put on them and clamped with special pliers. In this case, the walls of the sleeve are pressed into the conductor conductors and a reliable electrical contact is formed.

Advantages : high reliability; no high demands are placed on the performer regarding his qualifications; independence from the availability of electricity.

Disadvantages: rigid sleeve leads to wire rupture near the sleeve; it is necessary to have a supply of sleeves of various sizes; if the connection is larger than the diameter of the cord, the cable will touch surrounding objects.

How to connect to an inverter

The question of how to properly connect cables to a welding inverter arises when deciding on polarity when welding with direct current: forward or reverse.

The “plus” sign is connected to the electrode holder, the “minus” sign is connected to ground - welding is performed with reverse polarity . In this case, the current moves from the electrode to the workpiece, the metal heats up more than the electrode.

The “minus” sign is connected to the electrode, the “plus” sign is connected to ground, therefore, the polarity is straight. The current flows from the workpiece to the electrode, creating stronger heating of the electrode.

Which polarity should be used depends on several factors: the type of metal; workpiece thickness; electrode type.

More detailed information on how to connect cables to a welding inverter depending on the selected polarity is presented in the corresponding article.

You should also pay special attention to the basic rules for connecting welding cables to inverter-type equipment. These nuances will guarantee a safe and comfortable work process.

Reading this information will help you learn how to connect welding cables to a specific type of equipment.
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How to hold it in a holder

The method of fixing the welding cable depends on the type of electrode holder : homemade or purchased (produced by companies of the corresponding profile).

Types of homemade holders and methods of assembling them, their main advantages and disadvantages are discussed in the article “Electrode holder for a welding machine.” This article also presents a method for correctly and securely connecting the cable to the electrode holder.

You should also pay attention to the recommendations of the master , who will help you make a professional, competent holder yourself. For clarity, a video of the assembly of the holder is presented.

To understand how to connect welding cables to the purchased holder , we recommend that you watch the video below. The performer can clearly see that the cable, together with a metal gasket (plate), is inserted into the corresponding hole and securely fixed with a key by tightening the screws.

How to extend the cable on an inverter

Typically, the inverter is equipped with a wire no more than two meters long. Working with such a cable is quite problematic and inconvenient. Therefore, performers often have a question: how to extend the cable on a welding machine ?

Previously, we considered that connecting welding cables should be done in several ways, each of which is used depending on the skills of the performer, the presence or absence of specialized equipment and additional accessories.

Advice! In most cases, the owner of the welder connects the welding cables for the holder and the ground into one longer wire and uses it to connect to the ground . And for the electrode holder, the welder buys a part of the cable of the required length .

It is important to know how to extend a welding cable. The connection of welding cables during extension can be performed using the following methods: welding; soldering; crimping.

It is also worth noting the opinion of some professionals who are against lengthening the conductors . Cables that are too long may adversely affect the performance of the device. In addition, the longer the wire, the greater the current loss, which can negatively affect the quality of welding.

How to choose a welding cable

Equipment of any type will serve its owner for a long time if the wire is selected correctly. When choosing a conductor, you need to pay attention to the following points :

• the cable must meet the technical requirements for it: resistance to impacts, breaks, bends, aggressive chemical environments, temperature changes, ultraviolet radiation, mold formations;
• The cord must withstand the maximum current that the welder’s unit produces.

More detailed information is presented in the articles on KG, KOG cables, as well as in the publication on conductors for the inverter.

How to find out the cross section

The main technical characteristics of conductors: cross-section, diameter and other important properties are indicated in catalogs or corresponding descriptions. However, if the contractor does not have the opportunity to familiarize himself with this data, and the question of how to determine the cross-section of the welding cable needs to be answered, then you should remember some recommendations.

There are several ways to determine the cross-section of a conductor. They all boil down to the fact that first you need to calculate the diameter of the core. This can be done using a micrometer or caliper. However, the simplest method, which does not require special accessories, is to use the following method.

The contractor will need to remove the insulation from the conductive core. Then you need to wind the core around a cylindrical object (screwdriver) and use a ruler to measure the total length of the turns, the number of which for accurate calculations should exceed 10. In conclusion: the total length in mm. must be divided by the number of turns. The resulting value will be the diameter of the wire, from which the cross-sectional value can be found.

The contractor can find complete information about the cross-sections of cables of various brands in articles devoted to this topic:

• “Welding cable KG”;
• “Welding cable KOG.”

Source: https://WeldElec.com/svarka/post/osnastka/kabel/soedinenie-podklyuchenie-udlinenie/

How to connect welding leads to a welding inverter

The inverter welding machine has gained wide popularity among home craftsmen and small repair shops. To obtain a strong and durable seam, a powerful and serviceable machine is not enough. High-quality wires for the welding inverter of suitable cross-section, type and length are also required.

Device

Of the available metals, copper serves as the best conductor . Combined with its flexibility, this makes it an ideal material for making the base of welding wire - conductors.

The structure consists of the following main parts:

• copper core, twisted from a large number of copper wires with a diameter of up to 0.5 mm;
• separating layer - a thin shell that prevents the core and the insulation layer from sticking together, can be supplemented with talc or other powder;
• an insulating coating consisting of rubber, rubber or other polymer.

The ends are provided with contacts to connect to the inverter and holder. They are crimped and soldered to ensure the best contact.

Characteristics

The most important characteristic required for a wire is its cross-section . It determines the maximum current passing through the cable. No less important is the resistance, which causes electricity losses on the way from the device to the electrode. Mechanical parameters are of great importance:

• strength: ability to withstand loads;
• elasticity: the ability to return to its original shape after deformation
• temperature resistance: the ability to maintain working properties when temperature changes;
• ability to withstand sunlight and humidity;
• resistance to fungus and mold;

Kinds

With household and semi-professional class inverters, the most common in home workshops, single-core wires of the KG brand are mainly used.

Depending on their purpose and characteristics, they are:

• KG-HL , insulation is made of frost-resistant rubber, they work in the cold;
• KG-T , insulation impregnated with substances that prevent the growth of fungus and mold, used in humid climates
• KOG , highly flexible wires, for welding in hard-to-reach places, for example, in shipbuilding.

According to the number of cores they are divided into:

Single-core

Most of the inverter wires are single-core.

One wire connects the device terminals to the electrode holder, the other to the ground clamp on the workpiece.

Twin-core

Used for high frequency welding and alternating current operation . Two cores have their own insulation; the outside is covered with another insulating layer. Alloys of copper and other non-ferrous metals are used as materials.

Three-core

Such wires are used to connect automatic welding systems connecting pipelines and large containers.

Each core also has its own insulation.

Section selection

The correctly selected welding cable cross-section for the inverter will allow you to work safely and with the expected performance. If the wire cross-section is insufficient, the resistance of the wire will cause loss of current due to its heating; as a result, the machine will not be able to develop the required welding current and the quality of the seam will deteriorate sharply. In this case, the indicator on the inverter will blink , indicating an overload.

In order to connect low-power portable inverters operating from a 220V network, light and flexible wires with a cross-section of up to 16 mm2 are used.

For more productive devices, a cross-section of up to 50 mm2 will be required.

Correct connection

Proper connection ensures the welder productive and safe work.

Connecting wires to a welding machine requires compliance with a number of rules:

• there must be a terminal at the end, crimped or soldered;
• The wire cross-section must correspond to the maximum operating current of the device plus a margin of 20%
• You should carefully monitor the polarity of the connection and observe it;
• The cable must lie freely in the work area, without tension or loops.

How to connect a welding machine if there is not enough wire to the welding zone? You can increase its length.

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

When increasing the length, you need to understand that the longer the cable for connecting the welding inverter, the greater the losses and the lower the resulting current strength.

If it is necessary to weld at a great distance from the machine, wires of a larger cross-section should be connected to compensate for losses.

When splicing 380V cables equipped with terminals with a hole into a single circuit, they should be cleaned and securely connected with a bolt and nut, not forgetting to install large diameter washers. The connection point must be carefully insulated, taking into account the fact that the wire will be repeatedly pulled through metal and concrete.

How to connect an inverter if there is no crimped terminal on the cable? Wires are spliced ​​by repeatedly interweaving the wires that make up the core . Then the connection point should be soldered and crimped.

There are also special extension cables that have crimped and insulated connectors. Their type must match the connector of your device.

Manufacturers do not specify any restrictions on cable length. In each case, the welder himself decides what is better - to lengthen or drag the inverter and gas generator more often .

Marking of welding cables

The welding wire marking consists of several groups of letters and numbers. From it you can understand which model is in front of us.

First there are several letters indicating the type of cable.

After the type, a dash may indicate the climate class of the wire:

Next comes a number indicating the number of cores - 1, 2 or more. The designation is completed by the cable cross-section in mm2.

Safety requirements

When welding work, the following requirements must be observed:

• Do not work with wires with damaged insulation or insufficient cross-section;
• the wire in the working area should be placed freely, without clinging to the welder’s hands or feet;
• there must be enough light in the working area for the welder to move confidently;
• When connecting to the device, polarity must be observed.

Correctly selected wires for a welding inverter are the key to safe and productive work . You need to pay attention to the cross-section, length and climate class of the cable. Cable extension can be carried out in strict accordance with the requirements of the regulations.

Source: https://svarka.guru/oborudovanie/rashodniki-i-kompletuyushie/provoda-k-invertoru.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