How to properly connect the wires to the inverter

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 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.

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

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 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

Connecting a welding inverter

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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.

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

How to connect cables to a welding inverter

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.

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.

Source: https://MyTooling.ru/instrumenty/kak-podkljuchit-kabelja-k-svarochnomu-invertoru

How to connect the welding machine to the network?

Reading time: ≈5 minutes

So, you have purchased your first inverter welding machine. You will probably find an instruction manual included with it. Having carefully studied it, you will find that only a few general phrases are said about the correct inclusion. Is it really that simple? Plug the plug into the outlet and that's it? Alas, no.

An inverter-type welding machine is a complex device with its own nuances and features. By thoughtlessly plugging it into a household outlet, you risk losing the device itself or the wiring in the house. So how to connect a welding inverter correctly?

In this article we will briefly describe how to connect a welding machine to a 220 Volt home network and what should be taken into account.

Pre-check

Before you learn how to properly wire a welder, you need to make sure that the wiring in your home can handle the welding job.

Inspect the sockets, how old are they? If the outlets have not been replaced for more than 25 years, most likely all the wiring in the house is also old. This is not critical if it can withstand high current values. But often old wiring brings nothing but problems.

You are unlikely to be able to use modern welding wires with the machine if the power supply in the house is far from ideal.

You don't need to be an electrician to understand what will happen if you connect a powerful modern welder to old sockets. At best, you will be left without electricity. In the worst case, all your neighbors will be left without electricity, and your electrical appliances will simply fail.

In a word, check first whether your wiring can withstand the load. If you find that it can't, don't despair. This problem can be solved. We'll talk about this later. In the meantime, below is a diagram of connecting the welding machine.

Application of a current generator

So, you checked your wiring and it turned out that connecting a 220V welding machine is simply impossible. What to do in this situation? You can use a third-party current generator.

And at this moment, many immediately begin to remember that they keep an old gasoline generator in their dacha, which more than once saved them from sudden power outages. On the surface, the use of such generators seems like a pretty good idea, but in practice everything is different. Often, all gasoline generators are low-power and are not capable of providing a voltage of more than 5 kW for a long time.

As you understand, connecting a welding inverter to a low-power gas generator is simply pointless. To find out how much power you need, simply multiply the amperage you'll be cooking with by the voltage.

Let's take the most popular situation: you are welding with a 3 mm electrode with a current of 120 Amps and a voltage of about 40V. We multiply 120 by 40, we get 4.8 kW. This is the minimum power that a gas generator must provide. But in the calculations we did not take into account the efficiency of the welding machine, which is less than 100%. To ensure uninterrupted operation of the inverter you need at least 6 kW.

In general, a gas generator is a choice for those who no longer have any opportunity to obtain an additional power source. Ideally, before purchasing an inverter, you should check all the wiring and, if it is unsuitable, buy a welder with a built-in generator. Yes, these models are expensive and very bulky. But this is the most convenient solution to the problem.

If this solution is inconvenient for you, then you can buy a special current stabilizer for the welding machine. It connects directly to the welding inverter. This solution is suitable for a more or less stable power grid.

Use of extension cords

The topic of extension cords does not relate to connecting a welding machine, but these two issues are related. The fact is that if you select the wrong extension cables, the voltage may drop and the efficiency of the welding machine may decrease.

Why are extension cords needed? After all, the kit already contains quite long wires, usually up to 2.5 meters. At first this may be enough, but over time you will want more freedom for your actions. Especially if the device is heavy, and you need to move around the entire summer cottage or cook at height.

Therefore, we decided at the same time to tell you about connecting extension cables. First of all, remember that they cannot be used thoughtlessly. You need to accurately calculate what cross-section the extension wire should have. The maximum power that the wire can withstand will depend on this.

Let's give a simple example, using the same numbers from the previous example. Let's say we need a welding current of 120A. Wire cross-section 2.5 sq. mm. gives us 16A. Accordingly, for welding with a current of 120A, we need a wire with a cross-section of at least 12 sq. mm. We recommend choosing extension wires with a spare cross-section. Also remember to untangle them before welding so that it cools better. And don't forget about grounding. This is the simplest safety rule.

Also, do not buy several short extension cords and connect them together. It’s better to decide in advance on the required length and buy one wire. This way you will reduce the likelihood of a decrease in the efficiency of the welding machine. In addition, the contact connections of the extension cord will last you much longer.

Instead of a conclusion

Connecting the inverter to the grid is a simple process. You just need to learn everything once and then follow the rules. In addition, these rules also apply when you need to connect a 380V welding machine. If you have a transformer or semi-automatic in your arsenal, the algorithm of actions will not change either. We wish you good luck in your work!


Source: https://svarkaed.ru/oborudovanie-dlya-svarki/poleznaya-informatsiya-ob-oborudovanii/kak-podklyuchat-svarochnyj-apparat-k-seti.html

How to properly connect cables to a welding inverter

> On the computer > connect > How to properly connect the cable to the welding inverter

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To help the home craftsman: how to connect a welding inverter

Many home craftsmen have a welding unit in their workshop. It can be of different types. Today, specialized stores have quite a large selection of this equipment, including a welding inverter (image No. 1).

This is a unit that has certain advantages over other welding units. It has an attractive appearance, light weight, and great mobility.

It can be powered from a household and industrial network with a voltage of 220 V and 380 V, from batteries and generators producing a voltage of 12 V and higher.

Image 1. Diagram of the welding inverter.

Connecting the inverter to the power grid

The connecting cable supplied with the unit corresponds to the power of the device. You just need to check the technical data of the wiring in the house. It may turn out to be old and does not meet modern standards.

Nowadays, all wiring, switches and sockets, and safety devices are designed for an operating current of 16 A. Before connecting the welding inverter, you need to make sure of this. Although the installation should turn off itself if the diameter of the wires is small.

If everything is fine with the network, you can connect the inverter and do test welding.

If instead of a standard fuse, a “bug” is installed in the electrical network, the parameters of which are unknown, it is not advisable to connect the welding inverter to such a network.

Connecting the inverter to the vehicle's on-board network and to the generator

Functional diagram of the power source of an inverter welding machine.

Connecting a welding unit to a car battery is usually not difficult. Light weight of 2.5-3 kg makes it easy to transport the device to the car. Small dimensions of about 300 x 190 x 130 mm allow it not to take up much space. The connection is made as follows:

1. The inverter is connected to the battery.
2. Other necessary devices are connected.
3. If necessary, use an extension cord.
4. A test run of the machine and welding is carried out.

The device is connected to the battery using special clamps, observing polarity. The red wire clamp is connected to the positive terminal, the black wire to the negative terminal. When connecting the clamps to the terminals, a small spark may occur. If the inverter is designed for a voltage of 12 V, under no circumstances should you try to connect it to an on-board network of 24 V or more. You cannot connect multiple inverters at the same time.

Source: https://spravochnjksovetov.ru/na-kompyutere/podklyuchit/kak-pravilno-podklyuchit-kabelya-k-svarochnomu-invertoru.html

Connecting the welding machine to the electrical network: rules and algorithm, safety precautions

Surely, after purchasing an inverter welding machine, in the box you will find instructions for operating the device. After reading it, you will most likely notice that proper connection to the network will be mentioned in passing.

And in vain, because the matter is not limited to simply inserting a plug into a socket.

It is dangerous to carelessly connect such complex equipment to your home network without taking into account its properties and nuances. As a result, you can easily destroy the welding inverter itself or the wiring in the building. What do you need to know about properly connecting a welding machine?

Below we briefly summarize the main points that you should pay attention to when connecting a welding inverter to a 220V household outlet.

Preparing to connect

Before connecting the welding inverter, you should make sure that the wiring in the building is suitable for welding work. First of all, inspect the outlets.

If they were installed more than a quarter of a century ago, then there is a good chance that the wiring has not changed since then. It’s good if it can withstand high voltage, but this is rather an exception to the rule.

Usually such wiring only adds difficulties to the work. In this case, you will not be able to work with a modern inverter machine, even using the latest welding cables.

You don't have to have an engineering degree to imagine the consequences of connecting a powerful inverter to an old outlet.

You risk cutting off power not only to your workspace, but also to neighboring buildings, and electrical appliances may become unusable.

Before starting work and connecting the inverter, it is necessary to check the condition of the wiring. Don't give up if you find out that your wiring may not be able to handle the load.

You can get out of this situation by using a current generator. How to do this is described below. Now we suggest considering options for connecting an inverter welding machine to the network.

Using Generators

If the wiring test result is unsatisfactory, connecting the inverter is unacceptable. But there is always a way out. Electric generators can be used.

Many people have gas generators that can help out in the absence of electricity. In theory, their use may seem like a great idea.

In fact, it turns out that such generators have low power, and supplying a voltage of more than 5KW is an impossible task for them.

Obviously, there is no point in connecting an inverter device to a generator with low power. The minimum required power value can be found by multiplying the cooking current by the voltage value.

Let's consider a standard connection diagram. When welding with a 3 mm electrode and a current of 120A and a voltage of 40V, you need to multiply 120 by 40. This means the required power value is at least 4.8 kW.

Considering that the efficiency of the inverter is less than 100%, for stable operation of the welding machine you will need at least 6 kW.

So, a gasoline generator can be used when no other power source is available. It is more logical to check the wiring at the planning stage of purchasing an inverter device.

If it does not meet the requirements, there is a solution to purchase a device with an already built-in generator. The only disadvantages of these models are the price and large dimensions. But sometimes there is no other way to solve the problem.

If this option is not relevant for you, pay attention to the current stabilizer for the welding inverter. You can connect the device to it in a relatively stable network.

Selecting extension cords

Particular attention should be paid to the use of extension cords when connecting inverters to the network. If the extension cord is incorrectly selected, the efficiency of the welding inverter decreases and the voltage drops.

The configuration of welding machines usually includes a cable about 2.5 m long. For simple work, this length is enough, but in case of frequent movement or welding at height, it will not be enough.

Therefore, it will not be superfluous to learn about connecting extension cables. Under no circumstances connect them at random! You will need to calculate the exact cross-sectional size of the extension cable.

This value is directly related to the maximum power that the wire can withstand.

Using the above diagram, let's give an example. The current we need when welding is 120A. We get 16A when using a cable with a cross section of 2.5 sq. mm.

Proportionally, for a welding current of 120A, the cross-section of the extension cable must exceed 12 sq. mm. Do not forget about safety precautions, remember about grounding and untangle the cables before starting welding, for faster cooling.

It is much more efficient to buy one cable of the required length than to connect several short ones to each other. This way, the contact connections of the extension cord will be more durable, and the possibility of losing the efficiency of the welding inverter will be reduced.

CONCLUSION

The described technology for connecting an inverter welding machine to the network is simple.

It is worth understanding the importance of these rules, remembering them and successfully applying them in practice in the future.

When connecting a transformer, semi-automatic device or 380V device, the sequence of actions is the same. Successful work!

Source: https://prosvarku.info/tehnika-svarki/kak-pravilno-vypolnit-podsoedinenie-svarochnogo-apparata-k-elektroseti

We study direct and reverse polarity when welding

The direction of electron flow is controlled by polarity by switching the wires to the plus or minus terminal. That is, when working with DC welding, two settings are possible:

1. Straight polarity. The minus is connected to the electrode, the plus is on the ground terminal. In this case, the current moves from the electrode to the workpiece, and the metal heats up more.
2. Reverse polarity. The plus is connected to the electrode, and the minus to the ground terminal. The movement of current from minus to plus (from the workpiece to the electrode) creates more intense heating.

Direct and reverse polarity of connection when welding with an inverter is used depending on the tasks assigned and the quality of the materials. With alternating current, the type of connection is not important, but with direct current, it is possible to change the polarity manually.

Polarity value for welding

Direct current creates a thermal (anodic) spot. By changing the polarity, you can move it from the electrode to the workpiece. The main heating is created on the positive socket, therefore, with direct polarity, the workpiece heats up more, and with reverse polarity, the electrode heats up more. In this way, the capabilities of the inverter are formed depending on the characteristics of the metals:

• Metal thickness. With direct polarity, the main heat goes to the workpiece, so the width of the weld joint is quite deep. Accordingly, for thin metals it is more correct to use a reverse connection, in which the metal heats up less than the electrode.
• Metal type. When welding, you have to work with various alloys that have certain properties. For example, aluminum is a medium-melting metal, so you need to provide the workpiece with a direct connection for heating. It is better not to overheat stainless steel by choosing reverse polarity. The inverter settings allow you to take into account what kind of alloy is being cooked, so a preliminary study of the instructions will help you cope with the task effectively.
• Electrode type. Welding electrodes are coated with flux. When heated, it burns, fulfilling its main task: displacing air and preventing the formation of pores. The type of flux determines the features of using electrodes at different temperature conditions. For example, carbon electrodes are not suitable for connections with reverse polarity. The manufacturer's recommendations will help you make the right choice. The same applies to wire types. By the way, inverter semi-automatic machines also have characteristics that are worth taking into account.

If the workpiece and the electrode have characteristics that require conflicting settings, a compromise will have to be found by adjusting the current strength and weld processing time. With experience comes knowledge that allows you to solve any problem.

Manual arc welding using a consumable electrode (MMA)

Here its role is played by a special melting wire covered with slag. The method is very popular, but experts consider it not the best option for obtaining high-quality seams if the product is a complex alloy in composition. During melting, the wire connects the necessary parts, and its coating removes dirt and protects the weld pool from oxygen. The method is suitable for welding cast iron and ferrous metals.

Semi-automatic welding

The electrode is a wire that automatically enters the welding zone.

The device is in manual movement mode, so this method is not suitable for processing a large working area; it is used for welding thin sheets, non-ferrous metals, and high-alloy steel. Both direct and pulsed current are used.

When using flux-cored wire, gas is not needed; in other cases, current welding is carried out in an environment of active or inert protective gases. It is possible to weld with an electrode without melting it.

Gas shielded welding

The technological process involves the use of argon gas, which burns away dirt and oxygen compounds. The electrode is an infusible tungsten or graphite rod. The use of argon cleanses the weld pool from all unnecessary impurities and oxides. The formation of slag is excluded, the seam is high-quality and clean, but welding in a shielding gas environment is a rather expensive technology that requires serious skills.

Different types of welding are used and depending on the welding operating conditions. For example, to repair car bodies, services use semi-automatic arc welding using a shielding gas environment, which makes it possible to create high-quality welding work at a low cost. Direct and reverse polarity when welding with an inverter allows you to adjust the melting depth for any type of welding work.

Manual arc welding technology

Arc welding is the most common type of metal welding. The method is universal, technologically simple and allows you to obtain good quality welds in non-production conditions. The electric current of the welding source forms an arc between the workpiece and the electrode. The coating (flux) burns on it, releasing a gas that cleanses the work area of ​​oxygen.

According to the shape and types of connections, welding seams are divided into:

• T-bars;
• corner;
• butt;
• overlap;
• end

Different angles of inclination of the electrode allow you to create different types of seams. The most convenient interval is between 45 and 90 degrees, at which the weld pool is completely visible. With experience comes an understanding of exactly how to change the angle of inclination.

Typically, welding machines are equipped with a ground cable with a clamp-type holder. At first glance, it is convenient; such a device can be securely attached to almost any surface (sheets, rolled metal, etc.). But there are situations when it is not possible to install such a mass on the workpiece or, even more often, it burns out. A good alternative would be the magnetic contact of the welding cable.

Bottom line

The task for a beginner is to learn how to “make” a weld. The base metal is heated to the point of melting, forming a weld pool. Depending on the situation, the welder changes the current settings, focusing on the condition of the bath. You need to start with the settings recommended by the manufacturers, and then gradual practice will help you understand and correctly use all the capabilities of the inverter.

Source: https://electrod.biz/apparat/polyarnost-pri-svarke-invertorom.html

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/