How to change wires on a welding machine - Metals and their processing

Is it possible to lengthen the welding wires on the inverter - Machine tools, welding, metalworking

To work effectively, welders have to constantly move around the site, and the socket is located in only one place, so in most cases it is simply impossible to do without an extension cord. The most popular cable length that can make your work comfortable is 20-40 m, generally speaking. And in special cases everything is selected individually.

Theory

No matter how many of us love physics at school, it is the school physics course that we will need to remember in order to theoretically calculate the length of our extension cord. Let's remember that the resistance of a copper conductor is calculated as follows: R= 0.017 *L/S. Also in our case, we can use Ohm’s law for an incomplete chain I=U/R.

Let's decipher the letters in our formulas, which can take on any meaning.

0.017 – resistivity of copper cable; Copper is taken a priori, since it has the lowest value.
L - extension length, mm.
S is the cross-sectional area of the conductor, mm2.
U is the nominal voltage in the electrical network, V. However, the actual voltage should be measured, since the condition of most networks leaves much to be desired.
I—maximum inverter current, A.

From the formula R= 0.017 *L/S a simple and obvious conclusion follows: the resistance increases with increasing cable length (at the same time a voltage drop is observed) and decreases with increasing its cross-section. Accordingly, the length and cross-section of the cable must be selected in such a way as not to provoke a voltage drop on this cable.

You should absolutely not use home extension cords to connect household appliances. Manufacturers save on the cross-section of the cores of such carriers; they will certainly flare up when the inverter is connected. You should also not use conductors with a cross section of 0.75 mm2 or less.

In general, it should be noted that a 2.5 mm2 cable is enough for reliable operation at a current of 160A, you just need to make a “note in the margin” that the wiring to the outlet must withstand such a load.

Those who like to wind the cable into a reel when welding should be warned. The phenomenon of Faraday electromagnetic induction, which inevitably arises around a conductor with alternating electric current, has not yet been canceled.

And even if the induction in the coil is too low to lead to undesirable consequences, during prolonged welding the wire will still heat up (heating up to 70 ° C is considered normal). In a tightly wound coil, the cable does not cool and an increase in temperature will inevitably lead to melting of the insulation with all the ensuing consequences. troubles.

The copper itself will most likely remain unharmed, since it has a high melting point of 1080 °C, but the insulation will stick together. Conclusion: work on an unwound cable or, if this is not possible, on a loosely wound one, so that heat dissipation is ensured due to natural air circulation.

Practice

Let's return to the question: what cross-section should I take the extension cord?

Previously, we would have said that if you have a good network at home and the maximum current of your welding machine does not exceed 160A, then you can take 1.5 mm2 - that’s enough. It is faster for the circuit breaker to trip or for the inverter to go into overheat protection than for such a cable to burn out. It is very simple to check this statement: it is enough to place a 160-amp device on a load ballast and turn it up to the maximum current.

A cable with a length of 10 m x 1.5 mm2 can last a long time. In our case, the exposure was made for 12 minutes (arbitrarily, this time could be longer or shorter). During this holding time, the cable warmed up, but it was not so hot that it was impossible to grasp it with an unprotected hand (or it began to smoke). That is, a cable with a cross-section of 1.5 mm2 carries a load of 160A, but this, of course, is the limit and it is better not to allow this.

However, if you are not going to “scald” the whole day with the “four”, this option is quite acceptable.

Why do we not recommend taking a cross section of 1.5 mm2 today? Very simple. Because they don't report! You take a 1.5 mm2 cable, and it turns out to be 1.1-1.2 mm2. Conclusion: even if you have a good network, take 2.5 mm2. They may not report it either, but in any case this will be enough for household needs.

What length?

It all depends on your network and device. Example from practice. Carrying length is 120-130 m, welding with a Forsazh 161 machine from a shield and a good network: with a “troika” you can weld, but it’s quite difficult, but with an electrode ø2.5 mm you can weld freely and even cut something!

Which plug and socket should I use?

An ordinary 16A socket and simple high-quality plugs burn and melt at currents above 160A (but these are like consumables). When you buy, be sure to take a magnet with you to the store and “feel” the plug with it (the socket, however, no one will let you take it apart) - is it magnetic or not? Nowadays there are a lot of low-quality goods painted to look like copper or brass.

Source: https://stanki-info.com/mozhno-li-udlinit-svarochnye-provoda-na-invertore/

Is it possible to extend the welding cable on the inverter? — Metals, equipment, instructions

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.

Tungsten argon arc welding technology

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://spb-metalloobrabotka.com/mozhno-li-udlinit-svarochnyy-kabel-na-invertore/

Cable for welding machine: types, manufacturers

To carry out safe and high-quality welding work, it is necessary to responsibly choose a cable for the welding machine. It is its qualities that ensure the reliability and quality of the connection, guaranteeing the convenience and speed of the welder’s work.

Requirements

The inverter welding machine is equipped with two cables. One of them supplies current to the electrode, and the other (ground) is connected to the part being welded.

Any cable for a welding machine must meet four requirements:

Conduct current to the surfaces being welded with minimal losses (for this it is made either entirely of copper or copper-based. In this case, aluminum wire is added to it)
Be of the required length, thickness and weight (these requirements ensure the possibility of convenient operation without unnecessary movement of the device itself and minimal heating of the cable itself when a high frequency and current current passes through it)
Reliably isolate the conductive part from contact with the environment (here we are talking not only about obvious moisture, but also about metal surfaces on which welding work is often carried out)
Have high wear resistance (for an inverter welding machine, it should minimally change its properties under the influence of high or low temperatures, chemical reagents, and mechanical stress).

Characteristics of the cable for the welding machine

Neither domestic nor foreign manufacturers produce a universal welding cable suitable for all working conditions, but they produce a sufficient number of its types to satisfy all possible needs.

Products with similar characteristics, but with different markings, are used as a cable for a welding machine:

KS is actually purely welding.
KG – stands for “flexible”. The properties are almost identical to the first.

In addition to these two designations, several more markings are used; we will consider them in more detail.

Any cable is marked according to the same pattern: “A” “B” “C”x”D”

It means:

"A" is the class to which it belongs. As mentioned above, there are several of them - KS, CG and there is also its version KOG (especially flexible)

“B” - this place indicates the operating temperature range. If they are in the range from -40 to +50 degrees, then nothing is written, if from -60 , then the marking is CL (cold-resistant); if there are special antifungal and moisture-resistant additives, it is considered tropical and is designated as “T”. It can withstand up to +50 heat. When it does not burn at all, it is marked as non-flammable - “NG”.

“B” - a number equal to the number of working cores from 1 to 3 .

“G” - this last position indicates the cross-sectional area of the cable for the welding machine in square millimeters.

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Types of conductors used in cables

There are three types of conductors used as a base:

With one core - it is a set of copper wires twisted in a special way, covered with durable and flexible insulation. For example, this is the cable for the Resanta welding machine, popular among garage workers.
With two cores - in this option, both the cathode and the anode are combined side by side. Each of the cores is similar in design to the first type. The meaning of this design is the convenience of carrying high-frequency currents or alternating current.
With three cores - these are used in automatic welding machines for large-sized metal parts (for example, bridges, pipelines, tanks). The number of cores gives a high-quality and uniform seam.

Is it permissible to extend the welding cable?

Often, when working in cramped conditions or at heights, it is very difficult to move the machine itself behind the welder. It will be much easier to change the cable for the welding machine to a longer one. But this simple solution has its own nuances.

None of the manufacturers officially speak out in the documentation for their equipment about the permissibility of extension or its prohibition. Among the welders themselves, there is often a belief that extension is inadmissible due to the increased risks when working with such a device and the likely loss of manufacturer’s warranties in the event of breakdowns.

In reality, the length of the cable for a welding machine is not only possible, but also needs to be increased if operating conditions require it. The main thing to remember is that when extending it by one meter, its thickness must be increased by 40-50%.

If this is not done, then the resistance will become unacceptably high and it will begin to heat up uncontrollably, while the welding arc will shorten and will be poorly controlled even by an experienced welder. An attempt to level out current losses by increasing it as much as possible will result in the welding machine operating in overload mode. It will quickly begin to wear out and fail.

Tips and tricks

When choosing a cable for an inverter welding machine, you need to focus on three main indicators: its length, cross-section and external insulation. They influence the quality and safety of welding work.

In most cases, both when working in a small workshop and a large workshop, the most convenient and multifunctional is a copper cable for a welding machine with a length of two to three meters. This is exactly what all manufacturers complete their welding machines with.

When deciding to use a new cable, you always need to clarify the material of its conductive part. Since the requirements for copper and aluminum are significantly different, their dimensions also differ.

The cable is connected to the welding machine on one side and to the ground or electrode holder on the other side using special power connectors and plugs. You cannot use anything else instead of them.

When connecting the cable to the device, you must always observe the polarity of the current.

It is strictly not recommended to use the power cable of the welding machine to lift or drag it. These actions can most likely lead to mechanical damage to its shell. Subsequently, this may result in electric shock to the welder himself or third parties.

Despite the fact that the welding cable is very durable, flexible, resistant to heat and caustic chemicals, there is no need to test it again under critical operating conditions. First of all, for the reason that it is quite expensive, and besides this, it is likely that the person working in this way will be electrocuted.

Source: https://prosto-instrumenty.ru/kabel-dlya-svarochnogo-apparata/

Welding cable for inverter, connection to inverter welding machine, can it be extended, brand

The market for the production and sale of welding equipment offers a wide range of equipment of rectifier, transformer and inverter types. It is the latter type that is most widespread.

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

Welding cable design

To ensure the normal functioning of the inverter, wires with a copper base should be used. Copper is the best conductor of electric current. You should also use cords that are highly flexible. They simplify the work process and guarantee freedom of action for the performer.

The cable design includes the following elements :

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

Characteristics of welding cables

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

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

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Welding cable for inverter: types

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

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

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

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

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

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

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

You should also pay special attention to the following varieties:

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

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

Correct connection of welding cables to the welding inverter

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

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

Source: https://WeldElec.com/svarka/post/osnastka/kabel/dlya-invertora/

Is it possible to lengthen the welding cable on an inverter - Metalworker's Handbook

Reading time: ≈4 minutes

Included with any inverter is a welding cable. Its length, as a rule, is no more than two or two and a half meters. If you are a beginner, then extending the wires will not be a big problem for you. But for practicing craftsmen, the question is “is it possible to lengthen the welding cable on the inverter?” more relevant than ever.

Choosing an extension cord for a welding inverter is not as simple as it might seem at first glance. It is necessary to take into account the cross-section of the cable for the welding machine, what kind of cables there are, and what features need to be taken into account.

Types of extension cords

To figure out which extension cord is needed for a welding inverter, you need to know what you can buy in the store. Manufacturers offer two types of extension cords.

This is a standard welding inverter extension cord that simply allows you to be more mobile. The second type is extension cords, which not only increase the length of the welding cable, but also increase the size of the wire for the welding machine.

This type of extension cord is needed when your cables are not designed to carry the input voltage current when welded with a transformer.

Based on these features, you should start your choice.

Calculations

What else should you consider if you need to choose an extension cord for a reel welding machine? First of all, resistance. After all, the extension cord is the same current conductor as the welding cable itself. And it is designed for certain loads. Simply put, you need to know how much current the extension cable can handle.

To determine the resistance we need to know two formulas: R=ρ×L/S and I=U/R . Thanks to them, we will be able to accurately calculate what loads the extension cord must withstand.

S is the cross-sectional area of the cable (usually measured in square millimeters and indicated on the cable itself), L is the length of the extension cable, and ρ is the resistivity (depending on the metal the cable cores are made of).

Now the second formula. Here I is the value of the maximum current with which we can cook using an extension cable. U is the network voltage. It is important to indicate the actual DC voltage, and it is often less than 220V. This way the calculations will be more accurate.

Based on these formulas, it can be understood that the voltage on the welding machine largely depends on the resistance of the extension cable. The greater the resistance, the more the voltage drops.

Ideally, extension cables and welding leads should not significantly affect your electrical voltage. It is better to purchase high-quality ready-made extension cords in the store, they are the safest. In addition, before purchasing such cables it is easier to select the wire cross-section.

Application

So, you have selected and purchased extension cables. It would seem that it’s time to connect them and start welding. At this stage, many beginners make a number of mistakes, due to which the cables are not effective enough or do not work at all.

First, always straighten the inverter extension cord before use. Don't let it twist into knots or break. This applies to cables of any length.

Decide in advance what maximum length is optimal for you and do not buy too long cables, which will be wound into a reel for most of the welding. This is an irrational use.

In addition, when coiled, cables can cause increased induction. This is fraught with melting of the wires and failure of the inverter itself.

Also ensure that extension cables do not overheat during operation. Check the wires periodically and pick them up. If you can hold it calmly for a few seconds, then the temperature is not higher than normal. And if the cable gets so hot that you cannot handle it without gloves, then you need to stop welding and check the integrity of the cable.

Excessive heating of the cable also leads to failure of the welding machine and destruction of the cable itself.

As for storage, you need to be careful here too. Do not wrap the wires tightly, as this will deprive them of natural ventilation. Try to store cords in a dry, clean place and do not leave them outside or expose them to direct sunlight. Make sure that the connecting contacts and the cable plug do not become dirty or rusty.

Instead of a conclusion

You may need a welding cable extension in many situations. Welding a greenhouse or garage door, for example. And if for some a plot of 6 acres allows them to reach the standard cable to the welding site, then owners of large plots immediately face additional problems. We recommend that you purchase an extension cord anyway, even if you have never needed one. This way you will significantly expand your capabilities. We wish you good luck in your work!

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Source: https://ssk2121.com/mozhno-li-udlinit-svarochnyy-kabel-na-invertore/

Welding cable: wire size for welding machine, extension cable for inverter

We are talking about cables for welding machines. Its structure and, most importantly, the choice of a specific type for specific metal welding work is much more important than it might seem at first glance. Let's start with its functional purpose. and the only function is to efficiently supply electrical current to the electrode.

You know that we always prioritize the efficiency of welding work, which is determined by many parameters. One of the most important parameters of this kind relates to the characteristics of a special wire - its cross-sectional area.

This indicator must be kept in mind when choosing a suitable option without fail, as well as several other parameters: total length, characteristics of the local network in terms of possible voltage drop, and much more, which we will talk about now.

Types of cables

Naturally, the main determining factors in choosing a welding cable will be the properties of the machine itself for which it is purchased. The first thing is the current strength in the device. If, for example, it is 189A as close as possible, then the correct choice of wire to the inverter will be a KG 1x16 cable.

Types of welding cables KG.

It should be noted that all cables that are suitable for welding equipment are not cheap. Therefore, it makes a lot of sense to stop and think about what exactly you are going to do, and what kind of product you will need. There are a great variety of them on offer.

The structural varieties are as follows:

Selecting the cross-section of the welding cable

The cross-sectional area of the wire for welding is one of the most important parameters for the efficient operation of the entire device: such key indicators as the maximum maximum current strength and conductivity will depend on the cross-sectional area.

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The quality of overall welding work depends on these key indicators - the strength and aesthetics of the formed seam and the speed of operational work.

Wire brand and permissible load.

The cross-sectional area, which refers to small calibers, is approximately 7 mm². These products are designed for inverter devices of compact dimensions, which operate when connected to household electrical networks with a voltage level of 220V.

If you are dealing with industrial automatic welding equipment, you will have to deal with conductive cables with large cross-sectional areas - about 47 - 49 mm².

The line of this kind of products with a wide variety of cross-sections and braids is presented in numerous catalogs and tables that will help you choose the most suitable cable cross-section accurate to the millimeter.

In such catalogs, additional markings and maximum current strength with voltage, cord length and calculated weight of the equipment are indicated.

What happens if the cross-sectional area of your wire is smaller than the required size and does not fit the programmed power of the equipment in any way: the electric current will be generated in excess, as a result it will begin to concentrate on the fuse of the device.

You will not be able to work in such conditions, because at the slightest ignition of an electric arc, the device will instantly turn off to relieve the voltage.

Rules for connection and use

When connecting cables to inverter devices, there are a number of rules that you need to know and follow without fail:

To connect the device at its end there are welding connectors and special tips attached by soldering - plugs for the welding cable. The product should only be connected through them.
The wires can be connected to each other. This should only be done using special crimping. The main rule here is the mandatory isolation of connections between each other.
The cable is connected to power type connectors and electrodes through their holders. In this case, it is necessary to remember the polarity, which cannot be changed, except in cases where all current parameters are changed.
The welding cable for the inverter cannot be used for any other purposes - to pull the device towards you, for example.
A mandatory requirement is full technical compliance of the cable and the corresponding equipment in terms of rated power and all other parameters.

Cable extension: yes or no

This question most surprisingly continues to excite the minds of professionals and has been a hot topic of discussion for a long time.

Some believe that extension should never be carried out, because too long wires with connectors for the welding cable will lead to a decrease in the efficiency and quality of work.

On the other hand, if the wire is too long, voltage loss may occur. In this case, the arc will become shorter, it will be much more difficult to control, and the overall quality of welding will decrease significantly.

Criteria for selecting a cable for welding

The main criterion for selection is the stability of the welding process. This stability is influenced by many things - not only the indicators of the current and the mains voltage source, but also many parameters of the welding and mains wire.

Therefore, when choosing, we think about the correct length, the correct cross-sectional area and braid material - all three parameters are of serious importance. If, for example, the welding current reaches high values, the wire must be selected according to a certain type and material.

We have already said that all wires for welding machines have their own electrical resistance values. It can be calculated using tables, this is not a problem. For example, an aluminum conductor has a higher resistance coefficient than a copper conductor.

As a result of this difference, the aluminum wire for a power extension cord will require many more kilograms than copper wire. And the cross-sectional area of aluminum should also be larger.

Current load table.

Taking into account such facts, the extension of network wires is carried out using copper products in two versions: two- or three-core, with a length not exceeding forty meters. As for the cross-sectional area, it should be greater than 2.5 mm².

Choosing welding wires is a little different from choosing network wires. Products for welding are selected taking into account the strength of the output current; here, stranded copper grades with highly flexible braiding and improved insulation have a huge advantage.

The most popular wires for inverter welding are sold under the marking KG, which means flexible braid, or KOG, which means very flexible braid. These brands are distinguished by excellent insulation in several layers with an outer braid made of rubber materials.

The conditions of future work must be taken into account in advance without fail, because it is necessary to choose the most adequate type of insulation and resistance to mechanical damage, temperature conditions or aggressive chemical external environment.

The ability to read and understand welding cable markings can help you in this difficult matter:

If the marking looks like KG T 1x16, then this means a single-core product with a core cross-sectional area of 16 mm², in a tropical design with resistance to temperatures from -10 to +55°C.
Marking KOG HL 1x50: single-core product with a cross-section of 50 mm², frost-resistant and heat-resistant to temperatures from -40 to +50°C. In this case, the heat resistance index is not present.

The length of the wire and cross-sectional area must be consistent with the strength of the electric current and other parameters.

Let's sum it up

We dealt with the issue of choosing a welding cable, its marking, technical characteristics and parameters of their operation in extreme conditions.

The cable for a welding inverter is expensive, it is very undesirable to make a mistake with its choice; in addition to unnecessary expenses, you risk getting a whole set of troubles such as a short circuit or the inability to ignite an electric arc.

Source: https://tutsvarka.ru/oborudovanie/svarochnyj-kabel

How to properly connect a welding inverter plus minus

connection to the mains and battery

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 a 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 machine 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:

The inverter is connected to the battery.
Other necessary devices are connected.
If necessary, use an extension cord.
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 several inverters at the same time. Table of required technical characteristics for a welding inverter. You can connect devices necessary for operation to the inverter socket. When using an extension cord, you should try to keep its length no more than 50 m. When you turn on the device into the on-board network, the green LED should light up, which will burn as long as the battery maintains voltage within acceptable limits. If the voltage drops to 10.5 V and remains at this level for a minute, the welding unit will automatically disconnect from the network. The battery will have enough charge to start the car engine in the summer. Some welders try to use a low-power gasoline generator to power the inverter. If the generator power does not exceed 5 kW, then all attempts will be useless. The generator will operate at the limit of its power, causing frequent voltage drops. The inverter welding unit is very sensitive to such changes and may fail. Therefore, it is recommended to use an electric generator.

Wire for making an extension cord

Diagram of a welding inverter choke. To lengthen the wire, especially at the output of the device, it is not recommended to make intermediate joints. The cable must be solid along its entire length. Its total cross-section should be within 35 or more square meters. mm. Professional welders usually use KG brand wire. It consists of a large number of thin copper wires with a diameter of approximately 0.2 mm, woven together. Its total diameter must be at least 7 mm without shell. This cable is successfully used in AC networks with voltages up to 600 V and DC up to 1000 V. The maximum load that the wire can withstand depends on its cross-section. Wire brand and maximum load:

KG 1x16 189 A;
KG 1x25 240 A;
KG 1x35 289 A;
KG 1x50 362 A;
KG 1x70 437 A;
KG 1x95 522 A.

Connection diagram of the inverter to the battery.

Instead of the KG wire, you can use a KOG1 brand cable.

All connections using an extension cord are made following the rules:

For connections you need to use soldered or pressed lugs.
You cannot pull the inverter towards you using wires for this.
The wire must be selected in accordance with the rated power.
At home, it is recommended to use an extension cord up to 20 m long.
The extension cord must not be wound onto a reel to prevent overheating and failure due to inductance. Heating of the wire should not exceed 70° C.

KG brand wire is available in different versions. For work in conditions with severe frosts, the KG-HL wire is designed, capable of operating in temperatures as low as -60°C. In tropical climates, the KG-T cable works well. Its shell is resistant to mold and can withstand outdoor temperatures of +85°C. For places with increased fire hazard, the KGN cable is designed, the sheath of which does not burn.

Some useful tips

The place for welding work should not be cluttered.
It is not recommended to use the inverter in cold weather, in very dusty conditions, or near piles of metal shavings.
In conditions of high humidity, a canopy is required.
It is recommended to take regular breaks from use to allow the machine to cool down.
The duration of welding and rest are indicated in the instructions.
When working, you should use personal protective equipment. Be sure to use a jacket, gloves and a protective mask with a properly selected light filter.

The welding inverter greatly facilitates the welding process and allows you to obtain high-quality welds.

Source: https://respect-kovka.com/kak-pravilno-podklyuchit-svarochnyy-invertor-plyus-minus/

Welding cable

To operate an electric arc welding machine, it is necessary to create an electric arc discharge between the electrode and the workpiece. To supply current to the arc site, wires are needed. They must withstand very high current - hundreds of amperes. The conductivity of a cable is determined by its cross-section and the material from which its cores are made.

Welding cable

Types and purpose of welding cable

The welding cable is connected to a direct or alternating current source on one side, and to the electrode holder and ground clamp +85 °C on the other. Based on process requirements, it can be used in a wide variety of conditions.

Its main parameters are:

ability to withstand various mechanical loads and damage, stretching, compression, bending;
resistance to temperature changes;
resistance to radiation in the ultraviolet spectrum;
resistance to fungal and mold spores;
corrosion resistance.

Several main classes of cable are widely used. They are divided according to cross-section, number of cores and climate class.

Based on the number of cores there are:

Single-core. The conductor is made of copper wire, which has excellent conductivity and ductility. This provides flexibility for repeated winding/unwinding. Widely used in small-sized mobile inverter devices.
Twin-core. Two insulated conductors - cathode and anode - allow operation with high-frequency alternating current. They are made from special alloys of copper and other metals.
Three-core. Designed for automated welding systems for connecting pipelines and pressure vessels.

Three-core cable

The use of various insulating sheaths allows us to produce welding cables in different climatic versions:

Tropical (KG-T). The wire can operate up to +85 °C and at high humidity. Antiseptic impregnation protects it from bacteria and spores of fungi and mold. In tropical conditions, conventional welding wires do not hold up well and may break.
Cold-resistant (KG-HL). For insulation, special frost-resistant polymers are used that do not crack and retain elasticity in frosts down to -60 ° C

Design features

The cable design was developed and improved over many years, based on its operating conditions. The conductive core has a round cross-section and is woven from several stranded copper wires. Between the conductive core and the insulation there is a separating layer - a polymer film. If specially developed electrical insulating rubber is used, which prevents flow into the core, then a separating layer is dispensed with.

The design life of the welding wire is determined to be four years. After this, manufacturers recommend replacing it with a new one.

Welding cable cross-section

There is a renovation technology that involves removing worn insulation and applying a new layer of it. This allows you to bring welding wires back to life and extend their service life.

Types of conductors used

The following types of wires are used in today's welding equipment:

single-core copper, used together with inverter current sources;
twin-core high-frequency, used in pulsed welding and cutting of metal structures;
three-core for automatic welding complexes used in the installation of pipelines and pressure vessels.

The welding machine is supplied with wires designed for its maximum welding current. It is indicated in the device passport and on the plate on its case.

Welding machine complete with cable and mask

So, for a current of 160-190A, the wire cross-section must be at least 16 mm2. When the current increases to 250 A, the cross-section will need to be increased to 25 mm2, and for specialized professional models that develop a current of up to 500 A, a corresponding welding cable of 95 mm2 is needed.

Criterias of choice

The main criteria that guide the selection of cables for a welding machine are the following:

type (number of cores);
cross section (selected based on the maximum current);
length (determined by the distance from the device to the working one);
terms of Use;
compatibility with welding machine;
price.

Is it possible to extend the cable?

There is a lot of debate among experts on this topic. They argue about him “until they are hoarse, until they scream.” Some argue that the wire should never be lengthened, as this will lead to a decrease in productivity, safety and quality of the seam. Others argue that since the manufacturers' recommendations do not say anything about this, it can be extended.

The truth, as always, is in the middle. It is much more convenient to work with long wires if the welder has to constantly move from one welding point to another. Long wire means less transfer of the welding machine. The price for this convenience is an increase in cable resistance. To maintain arc parameters, you will have to increase the operating current, which can lead to overload and accelerated wear of the welding equipment.

There is a simple way out of this unpleasant situation: a longer cable should have a larger cross-section.

Cable extension

When replacing a wire with a longer one, it is important to correctly connect the plug and terminal connectors to it. This is done with mandatory soldering and subsequent crimping.

So, it is permissible to lengthen the wire, but at the same time it is necessary to increase its cross-section and carefully connect the connectors.

Selecting a cross-section when extending a cable

If it is necessary to extend the cable, it is important to adhere to the principle of maintaining its total resistance. According to the laws of electrical engineering, for a cylindrical conductor the resistance is directly proportional to its length and inversely proportional to its cross-section.

Roughly speaking, if the wire has become twice as long, then the cross-section of the welding cable should be twice as large.

If the increase in length is not multiple, then the cross-section of the new cable can be determined by the formula:

S2=L2/L1×S1,

where S2 and L2 are the cross-section and length of the new cable, and S1 and L1 are the old cable.

Features of operation and connection rules

When connecting cable wires to the welding machine, you must follow certain rules.

Polarity must be observed. On many sources that do not provide reverse polarity welding, the sizes of the plugs are made different, and it is simply impossible to connect the cables the other way around. If the sizes of the plugs are the same, you need to carefully monitor their markings.

It is necessary to ensure that the connectors are crimped and the insulation is intact. This is included in the mandatory check of equipment before starting work. It is strictly prohibited to work with a cable with damaged insulation or frayed wires.

Requirements for welding cables

The wire must ensure the supply of current to the arc site with the minimum possible losses. That's why they are made of copper - the strand has the highest conductivity of the available metals. To prevent the cable from being heated by the passing current, its cross-section is made large enough.

In addition, the welder is required to hold the electrode at different angles and often make complex movements with it. The wire should not hinder the movements of the welder’s hand. In addition, when assembling complex building and industrial structures, it is necessary to weld in hard-to-reach places. Therefore, the cable must be flexible, and the insulation material must be elastic and resilient.

Since metal structures, among which welding work is carried out, are conductors of electric current, the insulation must be strong, durable and withstand high voltages.

Also, the insulation must have high resistance to tearing, compression and torsion, resistant to extreme temperatures and aggressive environments.

Welding inverter in operation

During use, the wire is repeatedly wound into coils and unwound back. All of the above requirements are met by stranded copper wire of large cross-sections insulated with oil- and petrol-resistant rubber.

Welding cable marking

The marking consists of an alphanumeric designation.

It begins with an abbreviation meaning the class of wires. So, KS means “welding cable”, the letter K means that the conductor is woven from copper wire.

The KG (flexible) brand has very similar technical characteristics; it can also be used for welding at home.

The letter “P” means the presence of a polymer protective layer. The letters “ХЛ” indicate frost-resistant design. Such models can be used down to -60 °C. It is coated with an additional layer of polymer that prevents cracking in the cold.

The letter T stands for tropical design. The insulation is made of materials that can operate at temperatures up to +85 ° C and contain antiseptic and antibacterial drugs. This insulation also has the ability to operate in both very high and very low ambient humidity conditions, maintaining its high performance in hot deserts and mangrove forests.

The combination of COG indicates the applied cores of increased flexibility. Such cables allow you to stretch them into the most intricate corners of an assembled structure or a vessel under construction. In addition, it provides increased comfort for the welder when making complex welds with intricate patterns.

The letter HF means adaptation for high frequency currents. Such a wire will work perfectly with a welding inverter, both domestic and professional.

The combination of KG means increased water resistance. This wire can also be used to carry out work under water. This requires ensuring perfect waterproofing of all connectors.

And finally, GN means fire resistance or non-combustibility. Such models are used for “hot” welding in industrial enterprises, when a heat-treated workpiece (heated to the plasticity temperature) is subjected to welding.

Welding cable marking

Next comes the number 1, 2 or 3, indicating the number of cores. Then, through the “x” symbol, the cross-section of the conductor in square millimeters is indicated.

Manufacturers of imported welding cables use their own designation systems. Any store selling welding equipment has tables of conformity and interchangeability of domestic and imported models

Source: https://stankiexpert.ru/spravochnik/svarka/svarochnyj-kabel.html

Welding wires for inverter: cable applications, can it be extended?

To ensure efficient operation of the inverter, it is necessary to use power and welding cables of a certain cross-section and length. The wire for the welding inverter must have sufficient flexibility and match the power of the unit.

In addition, the wires used should not lead to a significant voltage drop; a drop of no more than 2 volts is considered acceptable.

Welding wire design

To ensure normal operation of the device, a copper cable should be used for the welding inverter. Copper is considered the best conductor of electric current. In this case, it is worth using stranded wires, since they have greater flexibility, which significantly simplifies the welding work and provides freedom of action for the performer.

Structurally, the welding cable consists of the following elements:

A current-carrying copper core consisting of many individual twisted conductors with a cross-section of up to 0.2 mm. In this case, the cross-section of the cable itself may differ significantly; on sale you can find welding wire with a core of up to 95 mm2.
To avoid short circuits or electric shock to the welder, the current-carrying core is covered with a layer of insulating material, which is usually rubber.

Such wires can be used to connect the unit to the power supply, ground it and supply current to the electrode holder.

KG brand cable

Among professionals, welding wires for inverters of the KG brand are in particular demand.

Manufacturers recommend using it in alternating electric current networks with voltages up to 600 volts; in addition, use at direct voltages up to 1000 V is allowed.

Depending on the power of the unit and the strength of the generated welding current, a wire of a certain cross-section is selected. Thus, a cable with a current-carrying core cross-section of 16 mm2 can operate at 189 A, and a 95 mm2 wire is operated at a current strength of up to 522 A. The most commonly used cable is KG 1x35, which can be used at 289 A (most devices operate in this mode) .

Depending on the properties of the insulating sheath, the welding cable for the inverter can be used in various climatic conditions:

KG-HL - the wire is intended for use in the Far North. It can be operated at ambient temperatures down to – 600C. The basis of the insulating shell is frost-resistant types of rubber.
KG-T is a cable intended for use in tropical conditions. Can be used in conditions of high humidity and temperatures up to + 850C. In addition, the insulation has a composition that prevents mold from appearing on the surface of the cable and is resistant to rotting.

In addition to this type of cable, in certain conditions, wire of the KOG brands (has increased flexibility) and KGN (the sheath is made of non-flammable material, such a cable is recommended for use when working in fire hazardous conditions) is used.

Cable extension

There are two opposing opinions on the question of whether welding cables can be extended. Defenders of this possibility argue that inverter equipment manufacturers do not set any restrictions on this matter, therefore, extending the cable is quite acceptable. This makes it possible to significantly simplify the work and provide the welder with greater freedom.

But do not forget that a significant length of the wire provides it with increased electrical resistance, which leads to a significant voltage drop and a decrease in the welding current.

This leads to difficulties when setting certain modes and performing welding work. Therefore, you still shouldn’t try to extend the cable yourself; the manufacturer offers the most acceptable option.

A few words about connecting the cable

The cable should be connected to the terminals of the unit using special lugs. This will ensure reliable contact and reduce voltage loss. Such lugs are connected to the wire by soldering or crimping. At the same time, during operation, you should not drag the device using the power or welding cable, this can lead to damage.

A correctly selected cable for the inverter guarantees high-quality and simple work.

Source: https://steelguide.ru/svarka/svarochnoe-oborudovanie/svarochnye-provoda-dlya-invertora.html

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

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