How to assemble a semi-automatic welding machine with your own hands - Metals, equipment, instructions
> Repair > How to make a semi-automatic machine from an inverter with your own hands
A good owner must have a semi-automatic welding machine, especially owners of cars and private property. You can always do small jobs with it yourself.
If you need to weld a machine part, make a greenhouse, or create some kind of metal structure, then such a device will become an indispensable assistant in your personal household. Here a dilemma arises: buy or make it yourself. If you have an inverter, it’s easier to do it yourself.
It will cost much less than buying in a retail chain. True, you will need at least basic knowledge of the basics of electronics, the availability of the necessary tools and desire.
Making a semi-automatic machine from an inverter with your own hands
Structure
It is not difficult to convert an inverter into a semi-automatic welding machine for welding thin steel (low-alloy and corrosion-resistant) and aluminum alloys with your own hands. You just need to have a good understanding of the intricacies of the work ahead and delve into the nuances of manufacturing. An inverter is a device that serves to lower the electrical voltage to the required level to power the welding arc.
The essence of the semi-automatic welding process in a protective gas environment is as follows. The electrode wire is fed at a constant speed into the arc burning zone. Shielding gas is supplied to the same area. Most often - carbon dioxide.
This guarantees a high-quality weld, which is not inferior in strength to the metal being joined, while there are no slags in the joint, since the weld pool is protected from the negative influence of air components (oxygen and nitrogen) by shielding gas.
The kit of such a semi-automatic device should include the following elements:
- current source;
- welding process control unit;
- wire feed mechanism;
- shielding gas supply hose;
- carbon dioxide cylinder;
- torch gun:
- spool of wire.
Welding station design
Principle of operation
When connecting the device to an electric network, alternating current is converted into direct current. This requires a special electronic module, a high-frequency transformer and rectifiers.
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For high-quality welding work, it is necessary that the future device has parameters such as voltage, current and welding wire feed speed in a certain balance.
This is facilitated by the use of an arc power source that has a rigid current-voltage characteristic. The length of the arc is determined by a rigidly specified voltage. The wire feed speed controls the welding current.
This must be remembered in order to achieve the best welding results from the device.
The easiest way is to use the circuit diagram from Sanych, who long ago made such a semi-automatic machine from an inverter and successfully uses it. It can be found on the Internet. Many home craftsmen not only made a semi-automatic welding machine with their own hands using this scheme, but also improved it. Here is the original source:
Diagram of a semi-automatic welding machine from Sanych
Semi-automatic Sanych
To make the transformer, Sanych used 4 cores from TS-720. The primary winding was wound with copper wire Ø 1.2 mm (number of turns 180+25+25+25+25), for the secondary winding I used an 8 mm2 busbar (number of turns 35+35). The rectifier was assembled using a full-wave circuit.
For the switch I chose a paired biscuit. I installed the diodes on the radiator so that they would not overheat during operation. The capacitor was placed in a device with a capacity of 30,000 microfarads. The filter choke was made on a core from TS-180. The power part is put into operation using a TKD511-DOD contactor.
The power transformer is installed TS-40, rewound to a voltage of 15V. The roller of the broaching mechanism in this semi-automatic machine has a Ø 26 mm. It has a guide groove 1 mm deep and 0.5 mm wide. The regulator circuit operates at a voltage of 6V.
It is sufficient to ensure optimal feeding of the welding wire.
How other craftsmen improved it, you can read messages on various forums dedicated to this issue and delve into the nuances of manufacturing.
Inverter setup
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To ensure high-quality operation of a semiautomatic device with small dimensions, it is best to use toroidal type transformers. They have the highest efficiency.
The transformer for operation of the inverter is prepared as follows: it must be wrapped with a copper strip (40 mm wide, 30 mm thick), protected with thermal paper, of the required length.
The secondary winding is made of 3 layers of sheet metal, insulated from each other. To do this, you can use fluoroplastic tape. The ends of the secondary winding at the output must be soldered.
In order for such a transformer to operate smoothly and not overheat, it is necessary to install a fan.
Transformer winding diagram
Work on setting up the inverter begins with de-energizing the power section. Rectifiers (input and output) and power switches must have radiators for cooling.
Where the radiator is located, which heats up the most during operation, it is necessary to provide a temperature sensor (its readings during operation should not exceed 75 0C). After these changes, the power section is connected to the control unit. When switched on.
The network indicator should light up. You need to check the pulses using an oscilloscope. They should be rectangular.
Their repetition rate must be in the range of 40 ÷ 50 kHz, and they must have a time interval of 1.5 μs (the time is adjusted by changing the input voltage).
The indicator should show at least 120A. It would not be superfluous to check the device under load. This is done by inserting a 0.5 ohm load rheostat into the welding leads. It must withstand a current of 60A.
This is checked using a voltmeter.
A properly assembled inverter when performing welding work makes it possible to regulate the current in a wide range: from 20 to 160A, and the choice of operating current depends on the metal that needs to be welded.
To make an inverter with your own hands, you can take a computer unit, which must be in working condition. The body needs to be strengthened by adding stiffeners. An electronic part is mounted in it, made according to Sanych’s scheme.
Wire feeding
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Most often, such home-made semi-automatic machines provide the possibility of feeding welding wire Ø 0.8; 1.0; 1.2 and 1.6 mm. Its feeding speed must be adjusted. The feeding mechanism together with the welding torch can be purchased at a retail chain.
If you wish and have the necessary parts, you can do it yourself. Savvy innovators use an electric motor from car wipers, 2 bearings, 2 plates and a Ø 25 mm roller for this. The roller is installed on the motor shaft. Bearings are attached to the plates. They press themselves against the roller. Compression is carried out using a spring.
The wire passes along special guides between the bearings and the roller and is pulled.
All components of the mechanism are installed on a plate with a thickness of at least 8-10 mm, made of textolite, and the wire should come out in the place where the connector connecting to the welding sleeve is installed. A coil with the required Ø and grade of wire is also installed here.
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Pulling mechanism assembly
Burner
You can make a homemade burner with your own hands, using the figure below, where its components are shown clearly in disassembled form. Its purpose is to close the circuit and provide the supply of shielding gas and welding wire.
Homemade burner device
However, those who want to quickly produce a semi-automatic gun can buy a ready-made gun in a retail chain along with sleeves for supplying shielding gas and welding wire.
Balloon
To supply shielding gas to the combustion zone of the welding arc, it is best to purchase a standard type cylinder.
If you use carbon dioxide as a shielding gas, you can use a fire extinguisher cylinder by removing the speaker from it.
It must be remembered that it requires a special adapter, which is needed to install the reducer, since the threads on the cylinder do not match the threads on the neck of the fire extinguisher.
Semi-automatic with your own hands.
You can learn about the layout, assembly, and testing of a homemade semi-automatic machine from this video.
A do-it-yourself inverter semi-automatic welding machine has undoubted advantages:
- cheaper than store-bought counterparts;
- compact dimensions;
- the ability to weld thin metal even in hard-to-reach places;
- will become the pride of the person who created it with his own hands.
Source: https://spb-metalloobrabotka.com/kak-sobrat-poluavtomat-svarochnyy-svoimi-rukami/
Homemade semi-automatic welding machine with your own hands: diagram, how to use it correctly
A semi-automatic welding machine can be homemade, made from an inverter. Let’s say right away that making a semi-automatic welding machine from an inverter with your own hands is not easy, but not impossible. Anyone who is planning to make a semi-automatic machine with their own hands from an inverter should study the principle of its operation, watch, if necessary, a video or photo on this topic, and prepare the necessary components and equipment.
To work you will need:
- An inverter machine that can generate a welding current of 150 A.
- Feeding mechanism for a semi-automatic machine (welding wire).
- Burner.
- The hose through which the welding wire passes.
- Hose for supplying shielding gas to the welding zone.
- Reel of welding wire (will require some modifications).
- Electronic control unit.
Semi-automatic welding circuit diagram
Particular attention is paid to redesigning the feeder, which feeds wire into the welding zone, which moves along a flexible hose. To obtain a high-quality, neat weld, the wire feed speed through the flexible hose and the speed of its melting must be consistent.
When semi-automatic welding, wire of different diameters and from different materials is used, so it should be possible to regulate the speed of its feed. This is done by the feeding mechanism.
The most common wire diameters in our case: 0.8; 1; 1.2 and 1.6 mm. Before welding, the wire is wound onto reels, which are attachments secured with simple fasteners. The wire is fed automatically during the welding process, which significantly reduces the time of the technological operation and increases efficiency.
The main element of the electronic circuit of the control unit is a microcontroller responsible for stabilizing and regulating the welding current. The current parameters and the ability to regulate them depend on this element.
Remaking an inverter transformer
You can make a semi-automatic welding machine with your own hands by remaking the inverter transformer. To bring the characteristics of the inverter transformer in accordance with the required ones, it is wrapped with a copper strip wrapped with thermal paper. Ordinary thick wire is not used for these purposes, because it will get very hot.
The secondary winding is also being redone . To do this you need:
- Wind a winding of three layers of sheet metal, each of which is insulated with fluoroplastic tape.
- The ends of the windings are soldered to each other to increase current conductivity.
The design of the inverter used for inclusion in a semi-automatic device must include a fan to cool the device.
When making a semi-automatic machine from an inverter, first de-energize the equipment. To prevent the device from overheating, place its input and output rectifiers, as well as power switches on radiators.
After completing the above procedures, connect the power section to the control unit and connect it to the power supply. When the power connection indicator lights up, connect an oscilloscope to the inverter outputs. Using an oscilloscope, look for electrical pulses at 40-50 kHz. There should be 1.5 µs between the formation of pulses, and this is regulated by changing the voltage supplied to the input.
Oscillogram of welding current and voltage: at reverse polarity - on the left, at normal polarity - on the right
Check that the pulses that are reflected on the oscilloscope screen are rectangular and their leading edge is no more than 500 ns. If the parameters being checked are as they should be, connect the inverter to the mains.
The current supplied from the output must be at least 120A. If this value is less, it is likely that a voltage not exceeding 100 V is flowing into the equipment wires. In this case, the equipment is tested by varying the current (plus the voltage on the capacitor is constantly monitored). The temperature inside the device is also constantly monitored.
After testing, check the device under load: connect a rheostat with a resistance of at least 0.5 Ohm to the welding wires. It must withstand a current of 60 A. The current supplied to the welding torch is controlled by an ammeter. If it does not correspond to the required value, the resistance value is selected empirically.
Usage
After starting the device, the inverter indicator should display a current value of 120 A. If the value is different, something was done incorrectly. Eights may appear on the indicator.
Most often this occurs due to insufficient voltage in the welding wires. It is better to immediately determine the cause of this malfunction and eliminate it. If everything is correct, the indicator will correctly show the current strength, which is controlled by special buttons.
The current adjustment interval provided by the inverters lies in the range of 20–160 A.
In order for the semi-automatic device to serve for a long time, it is recommended to constantly monitor the temperature conditions of the inverter. For control purposes, two buttons are pressed simultaneously, and then the temperature of the hottest inverter radiator is displayed on the indicator. Normal operating temperature is no more than 75 ° C.
If there is more, in addition to the information that is displayed on the indicator, the inverter will make an intermittent sound, which should immediately alert you. In this case (or when the temperature sensor is shorted), the electronic circuit will automatically reduce the operating current to 20A, and the sound signal will sound until the equipment returns to normal. An error code (Err), which is displayed on the inverter indicator, may also indicate a malfunction of the equipment.
When is a semi-automatic welding machine used?
Semiautomatic is recommended to be used when precise, neat connections of steel parts are needed. Using such equipment, thin metal is welded, which is important, for example, when repairing car bodies. Qualified specialists or a training video will help you learn how to operate the device.
Source: https://tokar.guru/svarka/poluavtomat-svarochnyy-svoimi-rukami-shema.html
Do-it-yourself semi-automatic welding machine: diagram - Welding
The capabilities of a semi-automatic welding machine are significantly higher than those of a machine designed for manual arc welding. A semi-automatic machine can weld much thinner metal.
The use of a special welding wire allows you to work with non-ferrous metals, and the use of shielding gas provides a weld of higher quality. Considering these circumstances, the desire to add such a device to your home workshop is understandable.
General information
If you can’t buy a semi-automatic welding machine, you can try to assemble it yourself.
It must be said right away that this task is not the easiest, and only those who have certain skills in working with electrical devices, have already repaired something, and understand circuits, can assemble a homemade semi-automatic welding machine. For those who decide to do this, we can recommend several possible assembly options.
Before planning work on creating a semi-automatic welding machine, you should study the principles of semi-automatic welding, as well as the design and operation of the device intended for this.
Semi-automatic welding machines are devices that carry out direct current electric arc welding using a special welding wire as an electrode in a shielding gas environment.
The wire is wound on a rotating spool and is automatically fed to the welding site, passing through a feed mechanism. The circuit of a semi-automatic welding machine can contain both an inverter and a transformer current source.
The welder lights the arc with his own hands and makes the seam, which is why the work is called semi-automatic. An analogue of the electrode holder in a semi-automatic welding machine is a torch that has a pistol grip with a button for turning on the wire feed.
The wire is fed through a thin channel passing inside the rubberized sleeve connecting the semiautomatic device to the burner. The channel for supplying gas during welding is located in the same sleeve and ends with a nozzle at the end of the torch.
Then the gas supply is turned on and the welding process begins. The wire and gas feed speed is adjusted by hand and by rotating the heads located on the front panel of the semi-automatic welding machine.
From a welding transformer
If you have an old welding transformer at your disposal, it can serve as the basis for assembling a semi-automatic machine with your own hands.
If the old device has a rectifier and successfully cooks with direct current, nothing else needs to be done in this part. If it is just a transformer for AC welding, it should be modified.
Diode bridge
In order to obtain a source of direct current for welding, the transformer must be equipped with a diode bridge and a filter. The diode assembly rectifies the secondary voltage, the filter smoothes out ripples, maintaining stable arc burning.
The rectified voltage of a single-phase transformer has the form of a sinusoid, the lower half-waves of which are reflected symmetrically to the abscissa axis and moved to the upper quadrants of the coordinate system.
Essentially, this is a voltage pulsating at a frequency of 100 hertz, reaching zero twice per period. Using such a voltage for welding as a constant voltage leads to an unstable arc. To eliminate this phenomenon, a filter is required to smooth out voltage dips.
Filter
The filter consists of a choke connected in series to the welding circuit and a capacitor connected in parallel. This combination of inductance and capacitance is called an L-shaped filter, because in the diagram, the elements connected in this way form the letter L.
The capacitor for the future semiautomatic device needs an electrolytic, polar, capacity of 10,000 microfarads, the more the better. The capacitor voltage must be at least 100 volts to have a good margin. You can solder several capacitors in parallel, and the capacitance is summed up.
Throttle
To wind the inductor with your own hands, you need to find an old transformer of suitable dimensions. A power transformer from old tube color TVs with a power of at least 250 watts is well suited for this purpose.
The transformer has two coils on an oval closed core consisting of two halves. The transformer is disassembled, the coils are removed, and the old wire is removed from them.
For winding, a suitable flat copper busbar is selected. On each coil, instead of the removed wire, two layers of turns of a copper bus are wound by hand. The coil should have 15 - 20 turns.
After this, the steel core is assembled, the coils are put in place, and a 1.5 mm thick textolite gasket is inserted between the halves of the core. The coils are connected in series.
Broach
You can build a wire drawing mechanism for a semi-automatic machine with your own hands, using small bearings and an electric motor from car wipers.
But it is better to buy a ready-made one; it is sold as a spare part for semi-automatic welding machines. You will also have to buy a torch and a hose through which wire and gas will be supplied.
From an inverter for manual welding
If the workshop has a welding inverter for manual welding, the problem with the power source for the semi-automatic machine can be considered solved. Based on a manual welding machine, you can make a semi-automatic inverter with your own hands.
In order not to disassemble a working inverter converter, you can proceed as follows. All additional components necessary for the operation of the semi-automatic welding machine can be located in a separate housing.
Case manufacturing
The task is to find or manufacture a suitable housing in which a reel of welding wire will be installed, freely rotating on a drum, and a wire drawing mechanism. On the front panel of this housing there will be a socket for connecting a hose with a torch and a wire feed speed regulator.
The negative terminal of the inverter must be inserted into a new housing and connected to the sleeve terminal. The welding wire must be connected to this potential.
Also inside the new housing, provision should be made for installing a hose connecting the shielding gas cylinder and the torch sleeve. To provide controlled gas supply, you can install a valve from a car windshield wiper.
Providing power to the broach and valve
Since the electric motor of the wire drawing mechanism and the valve that shuts off the gas are powered by a constant voltage of 12 volts, you will have to install a small transformer with a rectifier to provide this power.
To switch the motor and valve, it is better to install intermediate automotive relays at 12 volts. The wire drawing is turned on using a key on the torch, held by hand, to open and close the gas supply valve; a toggle switch is installed on the front panel.
This arrangement will allow you to use the inverter both for manual welding and as a power source for a semi-automatic welding machine. The costs of manufacturing a homemade semi-automatic device are low, but the benefits from it will be tangible.
Source: https://svarkaman.ru/oborudovanie/svarochnyj-poluavtomat-svoimi-rukami-shema.html
Setting up a semi-automatic welding machine - modes, adjustments, errors
Welding technologies are becoming more and more accessible, so everyone can now buy a simple inverter, and more practical buyers choose semi-automatic welding machines.
It would take a very long time to list the advantages of this technology, but in practice, owners are not always happy with their purchase. This is due to the fact that people simply do not know how to set up a semi-automatic welding machine.
We have analyzed the main functions of budget and middle-class devices in order to use an example of their capabilities to explain how a semi-automatic device is adjusted.
Before setting up
Adjustment of current, voltage, wire feed speed and other parameters is carried out immediately before welding; during the work, the welder makes additional adjustments to the work. However, there are a number of requirements and settings that must be completed before starting work, these are
- preparing the welding machine;
- as well as the conditions of the work performed.
Thus, the device must be connected to a protective gas supply system (carbon dioxide, argon or mixtures of gases). It is imperative to make sure that there is a sufficient amount of welding wire in the drum, and if necessary, insert a new one and stretch it to the working handle.
To correctly set the primary welding parameters you need to know:
Knowing these parameters and starting from the recommended values, you can set the recommended welding parameters, and then, based on your own feelings and quality of work, make adjustments.
Device settings
When everything is ready, you can begin the actual settings. Despite the fact that experienced welders can set the modes at their own discretion, we will build on the recommended parameters. The values presented in the table below are averaged and in each individual case, for better quality of work, it is worth making a small adjustment. How to do this, why this or that parameter is needed, we will consider further.
Table of approximate welding conditions for carbon steels
Gas flow rate
Although this parameter does not relate to setting up a semi-automatic welding machine, it plays an important role in the welding process. Modern gas cylinder equipment is equipped with convenient gearboxes, where the flow rate is indicated in liters. Just set the value to 6 - 16 liters, depending on the thickness of the metal and that's it.
Voltage
This parameter conditionally shows how much heat we will give to work at the moment. As can be seen from the table, the thicker the metal, the greater the Voltage, which means heating and melting occurs faster and easier. The difficulty in selecting voltage arises when we are dealing with non-standard metal or a special welding design. If we are talking about working with non-ferrous or high-alloy metals, then the optimal Voltage values can be found on the Internet.
On the other hand, some manufacturers do not indicate the exact value of this adjustment, but limit themselves to conditional indications, for example, numbers 1-10. In this case, you should carefully study the accompanying documentation, which should indicate the correspondence of the current position to the current voltage.
Thus, this parameter should be set according to the table “setting up a semi-automatic welding machine” or the manufacturer’s recommendations.
Wire feed speed/current
The second setting parameter for any semi-automatic machine is speed combined with current strength. This is due to the fact that both parameters are interrelated and by increasing the feed rate, the current strength increases. Some advanced machines have separate semi-automatic current controls, but they are of a professional level.
In more advanced models, the wire feed speed can be fine-tuned
As before, to begin with, we set the recommended values, however, during the process of work, this setting can and should be adjusted to suit your needs. The discrepancy is easy to spot. If the seam leads, strong deposits or shears are formed, then the speed is too high. If the roller “sags”, wavy depressions or tears appear, then the speed is too low.
By adding or decreasing the feed speed, you should achieve the ideal bead shape without bulges or seam sagging.
Most of the simplest devices have exactly two settings - voltage and feed speed, combined with current strength. By skillfully managing them, you can fully evaluate the quality of welding parts with a semi-automatic machine.
Extra options
In addition to the simplest devices, there are also more advanced models with advanced functionality on the market. Let's look at their capabilities and why additional settings are needed.
Inductance (arc setting)
The most popular function, which is actively being implemented even in budget-class welding, is inductance adjustment. The parameter allows you to control the rigidity of the arc and change the characteristics of the weld. Thus, with minimal inductance, the arc temperature and penetration depth are noticeably reduced, and the weld is more convex.
This setting helps to weld thin parts, as well as metals that are sensitive to overheating. At maximum inductance, the melting temperature increases, the bath becomes more liquid, and the penetration depth is maximum. The bead of such a seam is smooth, without bulges.
This mode is used for melting thick metal and working in corner joints.
Knowing how the arc reacts to changes in inductance, the welder can independently control the penetration depth and bath temperature to improve the quality of work and create more reliable critical connections.
High/low speed
The switch, which is marked as High/Low, in most models is responsible for more precise adjustment of the wire feed speed. We already know that every semi-automatic machine contains a similar regulator, but if your device can work with 0.6 and 1.4 mm wire, the boundary marks will be very different. That is why, when working with thin material, the toggle switch is set to the High position and the wire generally feeds faster, while the Low position is suitable for thick solder.
Note! Now there are hundreds of products on the market from dozens of different manufacturers, so in order to be sure what functionality a given model has, what this or that regulator and switch is responsible for, you should carefully study the operating instructions.
Why you can't rely entirely on recommended settings
A very popular question that worries every welding beginner. First of all, let's note a list of things that affect the quality of work:
- different fillings of semi-automatic welding machines;
- power supply quality;
- alloy composition;
- ambient temperature;
- thickness and grade of wire;
- spatial positions of work;
- composition of the gas or its mixture.
In total, in order to obtain a high-quality seam, the welder has to “get into” the optimal settings with which it is possible to weld products with high quality. But as soon as you take a different metal, change the position, or the network voltage drops, you need to look for those optimal settings again.
Common mistakes and ways to solve them
- Loud “crackling” noise during operation. Distinct clicks indicate a low solder feed rate. Increase this parameter until the operating sound becomes normal.
- Heavy splashing. Spattering often occurs when there is insufficient insulating gas.
Check the reducer, if necessary, increase the gas supply.
- Lack of penetration and burns are eliminated by adjusting the Voltage, as well as adjusting the inductance (if any).
- Sharp peaks or uneven bead width. Both problems are related to the position and speed of the torch.
In addition to welding settings, pay attention to your own work technique.
Conclusion
A semi-automatic machine is an indispensable assistant in any home or garage, but in order to get the most out of its capabilities, you need to pay due respect to studying the technical features of the device and the operating principle of semi-automatic welding. Thanks to this article, you know how to set up a semi-automatic welding machine. Don’t be afraid to experiment, look for exactly those parameters at which it will be convenient for you to weld the part and get a reliable seam.
Source: https://svarkagid.ru/instruktsii/kak-nastroit-poluavtomat.html
How to connect a feeder to an inverter
A semi-automatic welding machine is a functional device that allows you to weld various types of metal. Such a device can be purchased ready-made, or you can make it yourself from an inverter.
To make a semi-automatic device from an inverter will require a lot of effort and relevant knowledge, but if you strive, you can achieve your plan.
For those who decide to try assembling this device, you will need to research the scheme by which the semi-automatic machine works, watching various videos with photographs, and also get the required parts and accessories.
What is needed to convert the inverter into a semi-automatic machine?
To convert the inverter into a functional semi-automatic welding machine, you will need the necessary accessories and components:
- An inverter that is capable of generating a welding current of 150A;
- The mechanism responsible for supplying filler material and wire;
- A torch, which is an important welding device;
- The hose through which the filler material is supplied;
- A hose through which protective gas flows to the junction of metals for better formation of a seam;
- A filler material spool that will need to be converted for future equipment.
- An electronic unit that will ultimately control the process of a homemade semi-automatic machine.
An important point is the restructuring of the device to supply filler material to the connection zone, which passes through a flexible hose . In order for the process to proceed normally without any difficulties, it will be necessary to correctly implement the speed of movement of the filler material, for a more beautiful formation of the seam, in accordance with the melting of the wire.
It is necessary to pay due attention to the adjustment, because when working with a semi-automatic machine, wire of different materials and thicknesses can be used. This device was invented precisely because of this function, so the semi-automatic feed mechanism needs to perform it at the required level.
Wires for semi-automatic machines are used in different diameters, but the most basic and common are 0.8; 1; 1.2 and 1.6 mm.
Before carrying out the welding process, the wire must be prepared by winding it on the required reel, which is a semi-automatic attachment, which is attached to it thanks to simple design devices.
During the welding process, filler material is supplied automatically, which is very efficient in terms of time, which can be spent much more when working on other types of devices, thanks to this, the technological operation is considered much more popular and simplified.
The main part of the electrical circuit of the semi-automatic control unit is a microcontroller, the function of which is to regulate and stabilize the current for welding. It is precisely this part of the electrical circuit of a semi-automatic welding machine that produces the necessary current parameters for operation and makes possible adjustments.
How to rebuild an inverter
For the possible use of an inverter for a semi-automatic device, its transformer will need to be slightly rebuilt. To organize such a restructuring of the mechanism yourself, you just need to comply with the required rules.
In order for the characteristics of the inverter to coincide with the characteristics of the semi-automatic device, you will need to wrap it with a strip of copper, which should be wrapped with thermal paper. It should be remembered that in this case, it is not recommended to use a simple large-diameter wire, since it will still heat up .
It will also be necessary to redo the secondary winding of the inverter. In this case, you will need to wind a winding that is made of three layers of tin, all layers need to be insulated with fluoroplastic tape, and the ends of the finished winding must be soldered together with your own hands, thanks to which the current flow will increase.
The design diagram of the inverter used to connect it to a semi-automatic welding machine, it is recommended to purchase a fan, thanks to which the entire equipment body will be sufficiently cooled.
Settings of the inverter used for semi-automatic welding
If you decide to make your own semi-automatic welding machine using an inverter, you will first need to turn off the equipment. To protect the device from overheating, it is necessary to place its rectifiers (input and output) and power switches on radiators. Of course, the best way would be to mount a temperature sensor in the equipment case, where there is a radiator; it heats up more and will turn off the device if there is severe overheating.
When all the above steps have been completed, you can begin to connect the power part of the device with its control unit, and connect it to the electrical network.
You will need to connect an oscilloscope to the inverter outputs when the power indicator lights up. For such a device, it is necessary to obtain electronic pulses with a frequency of 40-50 kHz.
The formation between pulses will require a time of 1.5 μs, and they are adjusted by changing the voltage value that is supplied to the input of the device.
When all parameters correspond to the values, it will be possible to connect the inverter to the electrical network. The current supplied from the inverter output must be at least 120A.
When the current is low, then most likely the equipment wires have insufficient voltage conductivity, with a value not exceeding 100V.
In order to adjust the device to the required current supply, you will need to perform tests by changing the current strength (during the process, it is necessary to regularly monitor the voltage on the capacitor).
Also, you will need to always monitor the internal temperature of the case. If the semi-automatic machine passes all the tests, you will then need to carry out a load test. To do this, you need to connect a rheostat to the welding wires, which has a resistance of at least 0.5 Ohm. Such a rheostat must withstand a current of 60 A. In this case, the current strength that passes into the welding torch will be controlled using an adapter.
If the current strength at the time of using the rheostat with a load does not meet the requirements of the parameters, then the resistance value of such equipment is selected empirically.
How to use an inverter for welding
When the semi-automatic device, made by hand, starts up, a current value of 120 A will appear on the inverter screen. If the correct steps for manufacturing the device are followed, this value will be present, however, the screen may still show figure eights. This reason may be due to the fact that the voltage of the welding wires is not appropriate. It is recommended to eliminate the cause of such nuances immediately.
https://www.youtube.com/watch?v=8dR1RfoteHc
If everything is done correctly, the indicator will correctly show the current strength, which can be adjusted using the buttons. The operating current can be adjusted within 20-160A, which is provided by the inverter for welding.
Monitoring the correct operation of the device
In order for your semi-automatic welding machine to serve you for a long time at the required level, it is recommended to constantly monitor the temperature conditions of the inverter. For such control, you will need to press 2 buttons at once, due to which the temperature of the hottest inverter radiator will be shown on the screen. The normal temperature for operation is one whose value is no more than 75 degrees Celsius.
If this value is exceeded, in addition to the information displayed on the screen, the inverter will make noise, emitting intermittent sound signals, you must immediately take action on such sounds. In this situation, and in the situation of damage or short circuit of the temperature sensor, the electrical circuit of the device will automatically reduce the operating current to 20A, and sound signals will be heard throughout the entire time until the device is normalized.
Also, if your home-made device becomes malfunctioning or is damaged, an error (Err) will be displayed on the inverter screen.
When is a semi-automatic welding machine used?
Semiautomatic is recommended for use in situations where it is necessary to achieve precise, careful welding of various parts made of steel.
Thanks to this equipment, which was made with our own hands, it is possible to weld various thin metals, which is very popular in working with vehicles.
The welding process itself is simple and does not require long training, but you will still need to take several lessons from popular welders.
Source: https://respect-kovka.com/kak-podklyuchit-podayuschee-ustroystvo-k-invertoru/
Homemade semi-automatic welding machine from an inverter: how to assemble it yourself, instructions, diagrams
With experience, many professionals come to the conclusion that a semi-automatic welding machine is much more than a tool. This is a universal assistant in household welding both at the dacha and when repairing a car.
It does not limit you in the choice of material for welding and will be useful not only for the master, but also for the beginner.
Mass production of semi-automatic machines began just a few years ago. Old-school welders used to connect structures with huge transformers.
But technological progress is moving forward and has made it possible to create a portable and lightweight semi-automatic machine. Having appeared on the market, it quickly showed the world its advantages and sent the old models to rest.
Today, they have access to a variety of welding types: MMA, MAG/MIG, and TIG.
This was achieved because there is a regular inverter inside the device. It follows from this that a working semi-automatic machine can be made at home, using an inverter as a basis. At the end of this article, you will have all the tips and knowledge you need to do this.
How does a semi-automatic machine work?
Before you start working with any equipment, the first thing you need to do is familiarize yourself with its design.
Each semi-automatic machine contains two blocks: power and feed.
The power unit is represented by an inverter that supplies current. The feed unit is a separate device that is connected to feed the wire. A coil of wire is secured in the feed block, and the end comes out near the burner nozzle.
But for our purposes it is not really needed. You can do the wire feeding yourself, but this will slow down the work process and will be extremely inconvenient.
We have described to you the main elements of the device, but this is not enough. You will also need to order special parts needed for a specific type of inverter, as well as accessories (burner, sleeve, nozzle, etc.).
Workflow Features
Mastering semi-automatic welding is not as difficult as it might seem. After reading this article, even an inexperienced welder can handle it.
Let's start with how the burner works. The torch consists of two mechanisms that simultaneously provide the supply of shielding gas and wire.
The first can be adjusted independently, but the second is carried out in semi-automatic mode (this is how the corresponding name appeared). Because of this, the welder uses only the hand that holds the torch.
Let's return to the supply of shielding gas to the welding point. A mixture of gases surrounds the end of the wire and the top layer of material, and in this environment an electric discharge occurs that melts the workpiece with the wire.
The softened metal is mixed with the wire, and after that the weld can be made.
When welding, you cannot do without wire. Gas is also necessary because it prevents oxygen from entering the bath. But even in the absence of gas, you can use special cored wire.
Homemade semi-automatic
There are different approaches to creating a homemade semi-automatic welding machine from an inverter, but we will focus on the most practical and interesting ones.
By following these instructions, any beginner with basic knowledge of electrical engineering can do this at home.
Method No. 1
You can construct a semi-automatic welding device at home using a handy inverter. It is impossible to do without it.
A medium power inverter is suitable for MMA welding. It is important that it is in working order and can perform simple operations.
Next, you need to change the current-voltage characteristics (volt-ampere characteristics) to operate in semi-automatic mode. This is where a PWM controller comes in handy. Note that this approach is the most difficult and only experienced welders can handle it.
It is necessary to make a choke from a fluorescent lamp and switch the voltage to feedback. In the video below you can find out all the details and diagrams of this method.
Method No. 2
This method of assembling a homemade semiautomatic welding machine is very simple and can be mastered by almost every person who has dealt with inverter welding. Some inverter models can be switched to a mode with a rigid change in the current-voltage characteristic.
If you have such a device on hand, then you can easily make a semi-automatic machine out of it. All that remains is to order an external supply unit.
It is important to have the appropriate wires on hand. You just need to connect the feed unit to the inverter and you are ready to cook. In this case, the supply block acts as an addition. The video below demonstrates the features of this method.
Method No. 3
The last method of assembling a homemade semi-automatic welding machine will not seem so simple, because here you will need certain knowledge and skills. As in the previous case, you will also need a donor inverter.
You won’t be able to get by with just any device, because what is required is the assembly of the ZX-7 with a shunt at the output. The absence of arc forcing and hot start will only be beneficial.
Don't forget about the current-voltage characteristics, they also need to be changed. Next, adjust the current rise. Depending on the inverter assembly, further steps may vary from source to source.
We recommend that you read more information on special forums. In the video below you can take a look at the operation of a homemade semi-automatic machine.
Bottom line
This is all the information you need to make a homemade semi-automatic welding machine from an inverter. This tool will come in handy in cases where you don’t have a factory model at hand.
By remodeling it, you will not only save money, but also gain new electrical skills. This semi-automatic machine does not require careful maintenance and can be stored either in the basement or in the garage.
In addition, repairing the instrument will not take you much time and effort, since you perfectly understand what parts it consists of.
It is important to remember that a homemade device will not be your ideal assistant. It is not recommended to use it for a long time.
In many aspects and characteristics it will be much inferior to the factory models, and you will be taking a risk if you rebuild it in the field. For serious welding work, it will be better to purchase a tool in a store.
In this article, we were not able to cover all the nuances of self-assembly of a semi-automatic machine. But this information will be quite enough for you. It is possible to assemble it at home, but this process is quite difficult and not the most profitable.
Homemade equipment will almost always perform worse than factory equipment. Consider this before you decide to take such a step. We wish you good luck in your work!
Source: https://prosvarku.info/apparaty/samodelnyj-svarochnyj-poluavtomat
How to set up a semi-automatic welding machine yourself?
In order to correctly set the welding machine settings, it is not enough to read the operating instructions. It contains general parameters, and they are not always appropriate for the work that you are going to perform.
It is necessary to make more than one kilometer of seams in order to understand by eye how to weld this or that material. And for novice welders, we will explain in detail what to look for and what settings should be changed in a semi-automatic welding machine.
Basic rules when choosing a mode
It cannot be said that there is any specific optimal welding mode for all joints. In each individual case, it is necessary to proceed from the properties of the material, the characteristics of the workpiece, rotation angles, metal thickness, etc.
An ideal and durable joint is obtained only when all the nuances are taken into account. To understand this, try welding two parts with different settings. This way it will be clearer for you what will happen in the end.
But for those who are not ready to experiment on their own, we suggest using our advice.
When you pick up a workpiece and a welding machine, you need to imagine how much heat it will take to melt that metal. In other words, how quickly must the filler rod melt in order to melt the metal surface and enter into diffusion with it.
For thin materials, the amount of heat will be less, so as not to burn through, and for thick materials, more heating is required so that the heat penetrates evenly and deeply, leaving no unused areas.
Based on this simple conclusion, you can set the device settings as close as possible to the optimal parameters.
Now let's move from words to action. Current strength and arc voltage are the main indicators in the settings of a semi-automatic device. The feed rate of the additive depends on the current strength; the higher the current, the faster the wire moves. The current strength directly depends on the stable burning of the arc and vice versa. Only in the case of the correct regime and confident movements of the master, the joint will turn out to be correct and durable.
Basic principles of settings
During the welding process, even if you have set all the settings specifically for your type of work, you need to reconfigure them from time to time. Why this happens and what it is connected with, here are several factors:
- manufacturers of welding machines do not set themselves the goal of making all units the same, this is the point of such a range of products on the market. Each installation is intended for a specific range of work, which means that it is used not for a single part, but for a number of elements with their own parameters and properties;
- Power supply voltage fluctuations bring particular discomfort to the current supply settings. Someone can turn on or off a powerful electrical appliance, which will instantly affect the device’s settings. For such cases, you need to stock up on uninterruptible devices, otherwise the semi-automatic welding machine may burn out;
- if you change the gas cylinder, the settings need to be adjusted. Not all cylinders contain the same balanced mixture for everyone. The diameter of the filler rod is different from the previous one, in the case when you decide to replace it, even if it is of an identical brand;
- depending on the type of seam, you also need to adjust the settings or when replacing the coil;
We looked at the most common options when it is necessary to adjust the device mode settings. In most cases, such a procedure may not be required, but when changing gas or choosing another device, when using wire from another manufacturer, it is simply necessary to take into account the above settings.
How to set up semi-automatic welding equipment
If you have reached this stage, you probably already know how to use the gas settings and install the electrode correctly. We will talk about choosing the welding current and voltage, since these two points are the most important when welding. You must learn to choose the most favorable welding zone mode.
First, find a scrap piece of metal that you can practice on. Get him ready for work. Clean any dirt, rust or paint. Use a sander or sandpaper. Rub until shiny. This is the material that will be used for practical training. Don’t start straight away with a clean copy, do your homework on a rough draft, and after numerous attempts you won’t be able to mess up the necessary details. Although anything can happen.
The first step of finding settings
First, set the welding arc voltage. The recommended range is from 15 to 20 V. The next parameter will be to set the current to 100A. You hold the burner in one hand, and with the other hand you adjust the settings. Thus, you see the results of the settings instantly. Pay attention to the stability of the arc and the sound it makes.
A pleasant crackling sound should not resonate. Molten metal does not matter now, you must determine the current and arc parameters at which the work proceeds at the highest level. Turn the settings knob with smooth movements a little at a time, literally one or two notches. When you find the best option, these values need to be recorded.
Don't rely on memory, write it down or take a photo.
Second step of searching for settings
Here everything is much more complicated and painstaking. The previous parameters are recorded. Now reduce the current and leave the voltage at the same level. Reach the point where the arc burns on the edge, record the readings. Then increase the current to maximum, at the same voltage readings. Take notes.
At this point you have three parameters at constant voltage:
| Voltage V | Current strength A average values | Current A, minimum value | Current A, maximum value |
| 15-20 | 100 | X | at |
Record the following maximum and minimum current values as the voltage decreases by half a volt, then by another half volt, until the arc stops burning. Then set the settings to the average values with which you started the experiment and increase the voltage in the same sequence, fixing the strength of the welding current.
conclusions
Now you know exactly at what point of the bottom and top the device will stop working. You can draw a graph and hang it on the wall as a reminder. Make device settings within these limits. Also, do not miss, in the article - how a semi-automatic welding machine works - you will learn their main types and a detailed overview of the device.
Thanks to this knowledge, you will be able to configure the welding unit for any type of work with metal parts of various thicknesses, select modes for a certain size of wire or inert gas mixture. Also, do not forget that the instructions give values based on average temperature. In each specific case, it is necessary to configure the parameters individually.
Source: https://svarka-weld.ru/kak-samostoyatelno-nastroit-svarochnyj-poluavtomat
Setting the parameters of a semi-automatic welding machine
The semi-automatic welding machine is a very convenient device for working at home and in small workshops. You can work with it in any conditions, no special preparation of the workplace is required, it is compact almost like a regular inverter.
Unlike manual arc welding, it does not require a highly qualified welder to work with it. Correct setting of a semi-automatic welding machine allows even a low-skilled welder to perform high-quality work.
Depending on the type of material being welded and its thickness, it is necessary to correctly set the wire feed speed and shielding gas. Next, the welder needs to move the torch evenly along the seam, and a high-quality weld will be obtained. The whole difficulty lies in the correct selection of welding parameters for a specific material.
Equipment capabilities
To properly configure a semi-automatic welding machine, an understanding of the welding characteristics is required; it is also necessary to understand the features of the semi-automatic machine.
Semi-automatic welding machines allow you to work with almost any metals and their alloys. They can weld non-ferrous and ferrous metals, low-carbon and alloy steel, aluminum and coated materials, are capable of welding thin metals up to 0.5 mm thick, and can even weld galvanized steel without damaging the coating.
This is achieved due to the fact that flux, flux-cored wire or shielding gas, as well as welding wire can be supplied to the welding area, and the supply occurs automatically, everything else is done as in manual arc welding.
Semi-automatic welding machines are produced in different classes, but they all consist of:
- control unit;
- power supply;
- welding wire feed mechanism with reel;
- welding torch;
- power cables.
In addition, there must be a cylinder with a reducer and inert gas (carbon dioxide, argon or mixtures thereof), and a funnel for flux.
The wire feed mechanism consists of an electric motor, a gearbox and feed or pull rollers.
Recommendations in the instructions
Before starting work, it is necessary to reliably ground the welding machine and only then begin setting up. The semi-automatic welding machine must be connected to a gas cylinder system with protective gas.
It is necessary to check the presence of welding wire in the spool, if you need to reload it and stretch it to the torch handle. The gas supply speed is of great importance in the welding process.
Therefore, it also needs to be installed. Gas equipment has gearboxes indicating gas consumption in liters. This is very convenient; you just need to set the required flow rate within 6-16 liters.
The operating instructions for the device provide recommendations on how to properly set up a semi-automatic welding machine, what current to use to weld a specific metal, and at what speed to feed the wire.
The instructions should contain special tables in which everything is described. If you set all the parameters in accordance with them, then everything should work out.
In practice there may be difficulties. The quality of semi-automatic welding is influenced by many parameters. If the supply network does not meet the standards, then the power source will produce voltage and current that is not what is needed, the parameters will be unstable.
The temperature of the medium, the thickness of the metal, its type, the condition of the surfaces being welded, the type of seam, the diameter of the wire, the volume of gas supply and many other factors affect the quality of semi-automatic welding.
Tables of recommended welding conditions are given for certain conditions, which cannot always be achieved. Therefore, when welding semi-automatically, many adjustments are made experimentally.
Of course, the recommended values are initially set, then the welding parameters are fine-tuned.
Setting current and wire feed speed
First of all, the strength of the welding current is set, which depends on the type of material being welded and the thickness of the workpieces. This can be found out from the instructions for the semi-automatic machine or found in the relevant literature.
Then the wire feed speed is set. It can be adjusted stepwise or smoothly. With stepwise adjustment, it is not always possible to select the optimal operating mode. If you have the opportunity to choose a device, buy a semi-automatic welding machine with continuously adjustable wire feed speed .
The control unit must have a forward/reverse wire feed mode switch. When all the settings have been made in accordance with the operating instructions for the semi-automatic machine, you need to try working on a draft sample with the same parameters. This must be done because the recommendations are average, and in each individual case the conditions are unique.
At a high wire feed speed, the electrode simply will not have time to melt, there will be large deposits or shifts on top, and at a low speed it will burn out without melting the metal being welded, the weld bead will sag, and depressions or breaks will appear.
Adjusting parameters
Adjustment of current or voltage depends on the thickness of the workpieces. The thicker the product being welded, the greater the welding current. In simple semi-automatic welding devices, the current adjustment is combined with the wire feed speed.
In professional semi-automatic machines, the adjustments are separate. The correct setting can only be determined experimentally by making an experimental seam on a test piece. The roller should be of normal shape, the arc should be stable, without splashes.
Some semi-automatic models have inductance adjustment (arc settings). With low inductance, the arc temperature drops, the depth of metal penetration decreases, and the seam becomes convex.
This is used when welding thin metals and alloys that are sensitive to overheating. With high inductance, the melting temperature rises, the weld pool becomes more liquid and deeper. The seam bead becomes flat. Welding in this mode is used for thick workpieces.
The welding wire feed speed switch in models capable of working with different diameters requires additional adjustment taking into account the specific thickness of the wire.
Even after fully studying the manufacturer’s recommendations, it is not always possible to obtain the desired operating mode of the semi-automatic machine.
Having set the optimal settings for welding a workpiece today, it may turn out that the next day they will become suboptimal because the quality of the network has changed or the position of the product on the workbench has changed.
That is, setting the modes is a constant and individual process because it also depends on the work style of the welder himself.
Common mistakes
An error in the settings of the semi-automatic welding machine is indicated by a distinct crackling sound. Loud clicks indicate that the solder feed rate is low. It is necessary to increase the feed speed until the cracking noise disappears.
Heavy spattering of metal is often observed. This is due to an insufficient amount of insulating gas in the weld pool area. It is necessary to increase the gas supply and adjust the semi-automatic gearbox.
There are lacks of penetration or burns in the seam. This is due to the arc voltage being too low or too high and can be adjusted by setting the voltage or inductance.
The uneven width of the weld bead is associated with the speed of movement of the torch and its position relative to the seam, that is, it is associated with the welder’s working technique.
If you follow the manufacturer's recommendations and understand the processes occurring in the weld pool and how to adjust them, you can perform quite complex types of welding work at home.
Source: https://svaring.com/welding/teorija/kak-nastroit-svarochnyj-poluavtomat
How to properly set up a semi-automatic welding machine?
Many novice craftsmen want to learn how to set up a semi-automatic welding machine correctly. First you need to understand the operating principle and design features of the equipment. The fact is that a semi-automatic welding machine is not only a complex, but also an expensive device.
The spa is a multifunctional equipment. The normal operation of such a device depends largely on its correct settings before operation. Devices for carrying out welding work in a semi-automatic way are universal and practical.
At the moment they are considered one of the most common in the national economy.
Semi-automatic welding device.
The use of this equipment in everyday life allows you to produce high-quality welds. Using a semi-automatic machine, you can weld workpieces made of non-ferrous metals without the use of additional elements. During welding, carbon dioxide or argon is used as a protective medium.
Requirements for the welding process
The use of powerful welding equipment requires strict adherence to safety rules, since semi-automatic welding machines use high voltage and power current. Such current can be harmful to human health. If the operating instructions for such equipment are violated, a fire may occur.
If the semi-automatic device is configured incorrectly, it or its components may fail.
Electrical circuit of a semi-automatic welding machine.
Before starting work, you should configure the SPA accordingly. The idle operation of a semi-automatic device should not be associated with the delivery of operating current to the tip of the working sleeve.
Before welding, it is necessary to connect the grounding to a special terminal on the unit body. The device should be adjusted in accordance with the thickness of the metal being welded and its type. When manufactured, each device is equipped with instructions that contain setting tables developed by the manufacturer. They contain the operating parameters that need to be set when preparing the device for welding operations.
The process of setting up equipment is associated with monitoring the voltage and current on the welded wire, which acts as an electrode.
The technology for controlling the operation of the device involves performing the following algorithm of actions:
- turning on the microswitch;
- supplying voltage to the motor driving the wire coil;
- supplying voltage to the reversible winding of the coil motor;
- supplying voltage to the gas cut-off device.
During the preparation process, cut off the excess wire, leaving 3 mm from the end of the burner.
Setting up semi-automatic welding for welding work
Semi-automatic welding scheme.
You can adjust the dosage of supplying the amount of inert gas from a gas cylinder in two ways:
Correctly carried out preliminary adjustment of the semiautomatic device allows the formed electric arc to burn evenly, ensuring the welding process without the formation of splashes.
When welding, it is necessary to ensure that the metal does not boil at the welding site. To do this, you need to properly configure the device before use.
The gas supply to the welding area can be adjusted by ear, since the shielding gas makes a low noise when passing through the nozzle during the welding operation.
When regulating the gas supply to the production operation zone, you need to ensure that the protective gas does not blow into the metal melting zone, but blows it over it. If hissing sounds appear and the wire melts quickly, it is necessary to reduce the gas flow.
During operation, if all parameters are adjusted correctly, a stable electric arc is formed, which burns with a characteristic crackling sound. The quality of the weld is greatly influenced not only by the rate of supply of shielding gas, but also by its type.
Semi-automatic devices that allow changes in its operating parameters
Functional diagram of the power source of a semi-automatic welding machine.
The operation of any welding device is related to the functioning of the welding transformer in it. Semi-automatic devices use mechanical or non-contact methods for adjusting operating current parameters. When using a non-contact control method, the design of the device provides for the installation of a switching electronic board. This adjustment method is more preferable, since it has a significant resource in terms of switching.
The simplest device that allows you to configure the unit for operation is a throttle. It has several stages of adjustment when switching the lever. Each of them corresponds to an increase or decrease in the inductance level. Another device used in the design of the device for tuning is an active choke.
When used in the design of a welder, this device does not require mechanical switching during adjustment, which ensures smooth adjustment of the unit. The use of an active choke in the device makes it possible to more accurately adjust the welding machine.
The operating current when using a semi-automatic machine must be adjusted in such a way that the metal does not burn through during welding.
In order to correctly determine the required operating current parameters, when carrying out critical work, it is necessary to perform experimental welding on a metal plate made of the same metal as the workpiece that is being welded.
The change in welding current parameters occurs due to the use of a rheostat in the design of the device, which is the most effective device that allows you to change the current parameters.
Recommendations when setting up a semi-automatic machine
Semi-automatic welding panel.
The choice of welding current parameters should be made depending on the thickness of the metal being welded and the thickness of the wire used in the process.
Most often, during the manufacture of the device, a special plate is attached to it, indicating on it the recommended parameters for working with different wire diameters and metal thicknesses.
In the absence of such a plate with the recommended technical parameters of the welding current, you must follow the advice given by experts in the field of operation of semi-automatic welding devices.
Experts recommend that when using metal with a thickness of 1-1.5 mm, adjust the operating current in the range from 20 to 50 A, and as the metal thickness increases, the current should be increased. When the thickness of the metal being welded is 11-15 mm, the welding current should vary in the range from 170 to 280 A.
The strength of the operating current is greatly influenced by the thickness of the wire: the smaller the diameter of the consumable, the lower the current you can work with when welding.
The current strength is adjusted using a special switch, which is located on the device body. Additionally, the semi-automatic device uses a trimming rheostat.
If the current strength is incorrectly selected during operation, metal burning may occur, which leads to the appearance of a hole in the workpiece.
When selecting the required amperage and conducting test welding, it is not recommended to use metal with a protective layer of zinc on it, since welding releases a large number of harmful compounds.
When adjusting the speed of wire movement, it should be remembered that the movement of the consumable material has a certain degree of inertia, which, while the rotation speed of the coil remains unchanged, leads to a smooth increase in its movement immediately after starting the device.
After correct adjustments during operation, the welding wire should not spread after melting. If the current is insufficient, the wire does not melt.
Source: https://masterinstrumenta.ru/svarka/kak-nastroit-svarochnyj-poluavtomat.html
