How to replace a welding cable

Welding connectors for cables

Several decades have already passed since the Soviet times of total shortages, since those times when you had to wait in kilometer-long queues for anything of interest, or buy more expensively from resellers on the market.

Amateur welders who wanted to purchase a factory-made welding machine periodically looked into stores such as “World of Technology,” where they were constantly disappointed and, after a while, were forced to turn to local “homemade” ones.

Some welding transformers, created by the hands of folk craftsmen, were clumsy and unreliable, and some, on the contrary, were “well assembled” and served their future owners faithfully for many years, but both the first and second were bulky and heavy.

The plugs for the welding cable were not particularly sophisticated and consisted of a steel or brass pin with screwed-on washers and nuts (some craftsmen even turned special “lambs” on lathes to make it easier to quickly unscrew—tighten without a key).

The welding cable was inserted into copper cable lugs and flattened using special clamping pliers (most often just an ordinary hammer and a blunt chisel). The resulting cable shank was inserted through the hole in the tip into the stud and clamped with a nut (in those years, modern quick-release rubber-coated connectors for welding machines had not yet been heard of).

It cannot be said that when working at low currents, for example when welding structures with a 3-4mm electrode, these pins became very hot and failed, but they still caused certain inconvenience to welders.

For example, if it was necessary to switch the ends from a welding rectifier to change the polarity, then rarely did anyone turn off the device from the network, and when unscrewing the cables, the tips touched each other and “short-circuited”. 

And the bare pins themselves, sometimes protruding ten centimeters from the body, were not an indicative example of the correct manufacturing of the device from a safety point of view.

Those days are gone, the antediluvian transformers have been replaced by lightweight and high-tech welding inverters, which differ from their ancestors, for the better, in all respects.

In online stores, you can now find a lot of interesting models of welding inverters for manual arc welding at “delicious” prices, but if you look closely, you will see that their welding plugs differ in size (this is clearly visible if you pay attention to the mortise sockets on the front panel).

Welding plugs and sockets

In those models that we see on the shelves of market containers and hardware stores, there are two types of sockets for welding machines, and, accordingly, plugs: for cables with a cross-section of up to 25mm² and for cables of 35-50mm². The first type can withstand a current load of up to 200 Amperes, and the second type up to 300 Amps (with a standard generally accepted duty cycle of 60%). The length of the working part of the pin of the small welding plug is 12mm, with a diameter of 9mm, and the large one is 20mm, with a diameter of 13mm.

The mortise sockets have the appropriate diameters, but are made with a slight plus deviation to ensure excellent contact.
The working part of the connector plug for the welding machine is made of brass and has a square profile. On one side there is a hole for cable entry. The multi-core cable is inserted through a copper sleeve (if desired, it can be tinned), which is also included in the kit. Before inserting it, you need to tighten the rubber insulating sleeve onto it.

The coupling body, on the cable side, has a conical shape and special grooves along which excess can be cut off if the cable does not fit into the hole. The rubber insulation of the cable is removed to the length of the copper sleeve (15mm on the small plug and 25mm on the large plug). The cable is inserted into the sleeve and then into the brass housing. Fixation occurs due to a screw, when tightened, the cable is compressed through a copper sleeve in the body of the welding plug. Then the rubber coupling is tightened.

The plug is ready for use.

The socket for the welding machine consists of: a brass bushing with internal and external threads, a plastic insulating flange, a fastening ring, a nut, a bolt and two lock washers.

Insert a flange and a brass body into the hole on the body of the welding machine and press it with a ring on the back side (the flange has a guide, and the ring has a groove in the body). The assembled structure is pressed with a nut through a lock washer with external teeth, and then the cable lug coming from the inverter is tightened to it using a bolt with a washer and a groover.

By fixing the plug for the welding cable into the socket for the welding machine, a high-contact combination is obtained (connector), which allows the welder to quickly connect or disconnect the electrode holder or ground clamp without using wrenches or other tools.

How to extend the welding cable?

Very often, in order to attract buyers with price, manufacturers of welding equipment save on literally everything: the body is made not of steel, but of recycled plastic; the electrode holder is installed in the most primitive way; the mass clamp is similar to a clothespin, only made of metal; meter welding cables; the outer parts of the plugs are not made of elastic rubber, but of semi-rigid plastic; there is nothing to say about the “guts” of the welding inverter in such models.

The welding cable consists of many thin copper (sometimes bimetallic) wires of small diameter, which allows it to be flexible, and is enclosed in rubber insulation. On welding forums, in various articles about welding, the question of extending the cable for the machine is quite often discussed.

Some say that the cable cannot be extended, saying that this will affect the quality of the resulting weld, the performance of the inverter and the drop in power, while others say that there is no such “information” in welders’ passports, and everything that is not prohibited is allowed! We won’t argue, but short welding cables can cause some inconvenience.

Of course, you can cook by hanging the inverter through a belt, on your shoulder, and the length of the cables is not needed longer than the length of your arm, but if the inverter is heavy (there are models weighing 8 kg), then why hold it on your shoulder when you can put it on the floor.

With short native cables, you can observe a picture when a welder, welding something on the ceiling and standing on a table, puts the device on a stool (so that it is closer to him) and works like this, running around the table with the stool. Inconvenient. There are special portable sockets for extending welding cables.

They look like welding plugs for a cable, but their working part is not a brass cylinder with a protrusion for fixing, but a socket with a hole and a groove for this protrusion. If your welding inverter has one and a half or two meter cables and they do not suit you, that is several extension options: use a copper crimp bushing, connect through cable lugs and tighten them with a bolt and nut; twist and solder or use modern high-pin portable sockets.

We take the cable, install a portable socket on one side, and a welding plug on the other - the extension cord is ready. If the need arises, then remove the standard electrode holder with cable, insert an extension cord into the welding inverter, and then insert the electrode holder into it. Using the connectors is simple and convenient. And in situations where you really need to work, with an inverter hanging on your shoulder, we put the extension cord on a shelf and work with the standard set (extra welding cables will only get in the way).

Good luck in all your welding endeavors!

Source: https://e-1.com.ua/articles/14

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

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:

Single-core

This welding cable is made from copper wire, which is distinguished by its elasticity and flexibility. In addition, the distinctive quality of copper as a metal is known - it is an excellent conductor of electric current.

These types are usually used for compact portable inverter devices with low power and corresponding parameters of current strength and other technical indicators.

Twin-core

This configuration has a cathode and anode, which are excellent at conducting electrical current during pulse welding.

Most often, these wires consist of pure copper wire, although there are products made of copper alloys with the addition of other metals that conduct current well. But the base is copper in any case, this is an important condition.

Three-core

This type is produced for complex automatic welding equipment, for example, powerful pipelines for transporting oil, gas or their products.

Such work is considered highly responsible with mandatory requirements for the formation of ideal welding seams.

The marking of wires contains all the technical characteristics of welding work, which greatly simplifies their selection for specific work:

• KS - the product can be used in various types of welding work.
• P - the product is covered with an additional layer of polymer material for additional protection of the conductor. If there is a number next to it, it shows the number of cores in the cable.
• HF – the product can be used at high frequency voltage.

Welding cable marking.

There are other useful properties of welding wires. They have excellent resistance to high and low ambient temperatures with a wide range from -50°C to +50°C, they are resistant to moisture and other aggressive external factors.

Most often, welding wires for an inverter come together as part of a common package in modern welding equipment. But they can be purchased separately as consumables. In this case, you need to look for products with the same markings as they were originally.

According to their resistance to environmental conditions, all products are divided into two large groups:

• Tropical or antiseptic under the KG-T label can withstand temperatures up to +50°C in combination with high humidity. In such conditions, there is a high risk of fungal mold or the proliferation of pathogenic microorganisms. If the braid is not specialized, it can easily become exposed in the heat of the desert or in the tropics.
• Cold-resistant or cold-resistant under the marking KG-HL. The polymer braiding in them is absolutely resistant to frost, so the wire does not freeze or crack in the cold down to -60°C, that is, in the most severe climates.

Safety requirements

Like any other device designed to work with electricity, welding wires are subject to strict requirements and mandatory high safety standards.

The main safety requirements can be divided as follows:

• The cross-section of the core must be able to withstand the required electrical load, that is, the cross-sectional area must be adequate.
• The body of the wire must withstand mechanical stress, as well as the influence of an aggressive chemical environment. These conditions are met using the correct braid made of polymer materials.
• Usually the wires are twisted many times. This fact should not affect the integrity of the braid - it should be elastic and resilient.

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.

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.

  Designation of welding seams on GOST drawings

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://stanki-info.com/mozhno-li-udlinit-svarochnyy-kabel-na-invertore/

Welding wires for inverter

The distance of the welder from the location of the welding machine is determined by the length of the welding wires. And this is the possibility of unlimited movement to the required welding point, plus the convenience of the welding process itself. But welding wires are selected not only according to this criterion; it is very important to select the correct cross-section for the power of the inverter, and also take into account some of the characteristics of the wire itself. Namely:

• High flexibility of the cable, which allows you to change its position in space due to the fact that the location of the welder himself changes.
• Insulation strength, because welding operations can be carried out in different conditions, where the cable itself will be affected by mechanical loads, humidity, technical materials, different temperatures, and so on.

Based on this, special requirements are placed on welding wires.

Primary requirements

Any, even the most low-power inverter, produces a current of sufficient magnitude to cripple a person. Therefore, very stringent requirements are imposed on the electrical safety of wires for a welding inverter. Some have already been mentioned above, but let’s look at them in more detail.

The insulation of the welding wire, or as it is called - braid, is made of a durable polymer composition. It is this polymer layer that creates the conditions under which the cable can easily be subjected to shock loads, the negative effects of moisture and chemically aggressive materials.

At the same time, the polymer works perfectly in tension, so ruptures in the insulation body will never occur. And this could happen, because during the welding operation the wire bends in different directions, and quite intensely.

Plus, the welding cable is stored in a coiled state, so the braid must withstand repeated winding and unwinding.

Some models of welding cables are covered with a rubber sheath. This is a more reliable option, because in addition to rubber, there is a polymer layer inside that separates the metal copper conductors from the rubber. When heated, the metal does not stick to the rubber hose. And this greatly extends the life of the wires.

As for the cross-section of the wire, as mentioned above, this indicator depends on the current strength supplied to the electrode.

For inverters delivering a maximum current of 180 amperes, a cable with a cross-section of 16 mm² is suitable; for devices with a current of 100 amperes, a cable with a cross-section of 7 mm² can be used. For a current of 220 amperes, the KG 25 brand with a cross-section of 25 mm², whose outer diameter is 15 mm, is suitable.

The cross-section of the KG 35 wire is 35 mm², and this cable can withstand a current of 270 amperes. Most often it is used to connect welding transformers.

It is very important to correctly correlate two parameters: cross section and current. For example, if the cross-section of the wire is insufficient, that is, it does not correspond to the rated current value, then the electricity simply will not pass beyond the fuses of the device, where it will condense, that is, accumulate. In this case, the fuse will simply turn off.

If the cross-section of the wire is large, greater than the required current, then the likelihood of a short circuit in the device itself increases sharply. This often leads to failure of the inverter itself.

Classification of welding wires

Currently, cable manufacturers offer three types of welding wires, which differ from each other by the current-carrying copper core. Or rather, their number in one braid.

• Single core wires. In essence, this is a single monolithic copper wire with the appropriate cross-section. Typically, such cables are included with portable welding machines. That is, this is a class of welding wires for inverters.
• Twin-core. Such welding wires consist of two wires insulated from each other, performing the functions of a cathode and anode. The conductors are made from pure copper or its alloys.
• Three-core. This type is used for welding automatic welding equipment, which is used for welding large diameter pipes.

In addition to this division of wires for a welding machine, there is another type of classification, in which there are two groups.

1. So-called septic cables for welding. They are used in conditions where the temperature should not exceed 50C.
2. Resistant to low temperatures. Such cable products are treated on top with a polymer that can easily withstand sub-zero ambient temperatures. It is this polymer that protects the main insulation from cracking in the cold.

In order not to make a mistake in choosing a welding wire for an inverter, you need to buy the device itself, which also includes a cable. The thing is that manufacturers of welding equipment adjust the characteristics of the cable to the characteristics of the inverter. If you need to replace an outdated or worn-out wire with a new one, then it is better to purchase it of exactly the same brand as the old one.

Modern welding cables

The KG cable has already been mentioned. It has recently begun to be used as a welding machine, although its main purpose is lighting systems. Its main difference is its multi-core flexible design. But in order to make the KG cable weldable, manufacturers were required to use more reliable insulation, because the currents passing through the wire during welding are significantly higher than in lighting systems. Although the copper core itself can cope with such loads easily.

So, elastic rubber is used as insulation in the CG cable. Some models have double insulation, so to speak, a hose within a hose. Manufacturers now offer models that can be used at high and low temperatures.

The first is marked as KG-T. The main feature of the braids of this wire is not only to withstand high temperature operating conditions (up to +85C), but also the ability to resist the formation of mold on the surface and inside the cable. And mold quickly deals with copper wires, filling the space between the veins.

The second position is marked as KG-HL. The insulating braiding includes a layer of cold-resistant rubber, which resists low temperatures (down to -60C), so welding wires of this brand are recommended for use in the regions of the Far North.

It is necessary to identify another modern type of welding cable, which allows you to replace other brands, including KG. This is a flexible option under the KOG1 brand.

It has a stranded copper core and a rubber hose insulation made from a mixture of natural and butadiene rubber. This wire can be welded under any conditions, that is, at a maximum temperature of +50C, at a minimum of -50C.

The hose can be completely immersed in water and can be used under the sun. It doesn't burn or tear. It can be connected to inverters, automatic and semi-automatic devices.

To summarize, it should be noted that no matter what welding wire is selected, it is necessary to take into account those parameters that determine the welding mode. Its high-quality and long-term operation will depend on this.

Source: https://svarkalegko.com/oborudovanie/svarochnye-provoda.html

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

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://respect-kovka.com/mozhno-li-udlinit-svarochnyy-kabel-na-invertore/

How to connect cables to a welding inverter

A welding inverter is a device that can greatly facilitate the arc welding process. Every year its use becomes more and more popular, because it allows welding of any structures quickly and efficiently. In order for welding work to take place in the required modes, and for the device to have a long service life, you need to correctly connect the inverter to the power source. Therefore, further we will consider how to properly connect a welding inverter.

Diagram of the device of an inverter welding machine.

Connecting a welding inverter

The welding machine can be connected to an external network with a voltage of 220 V or 380 V, or to a generator set of a certain power. The connecting cable with plug corresponds to the maximum power of the unit, so there should be no questions here. The main difficulties may arise from an external power source, especially if the electrical wiring in the summer cottage is old and has an unknown cross-section.

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

Welding inverter device.

One of the advantages of this type of welding devices is that their electrical circuit has several types of protection. In case of network overload, the protection automatically turns off the device due to low voltage. This situation can occur when the input voltage is low, or in the case of insufficient electrical wiring, the resistance of which will reduce the voltage when a load in the form of welding current occurs.

If the electrical wiring of a fixed network does not allow connecting an inverter, you need to use other power sources, which will be discussed below. If the maximum power of the device fully matches the external wiring, you can connect the inverter to the mains and carry out test welding.

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

If possible, you need to control the voltage drop when igniting the arc. Severe subsidence may be the result of a small cross-section of wires.

Connecting a welding inverter to an electric generator

Due to poor parameters of the external electrical network, in some situations it is simply impossible to carry out welding. Then you can use the power plant. At the same time, it is very important that the power of the power plant allows for full-scale welding work.

When choosing a generator, you should first familiarize yourself with the basic technical characteristics of the welding machine. As an example, we will take a conventional inverter with an operating current of 160 A. Modern inverters have smooth adjustment of the welding current from minimum to maximum value. This allows welding to be carried out at both medium and maximum power of the equipment. But manufacturers often write only power consumption, without saying anything about its maximum value.

Figure 1. KG brand wires are different and differ in maximum load, depending on the cross-section.

To independently calculate the maximum power, you need to multiply the maximum operating current of the device by the arc voltage (usually it is 25 V), and then divide the resulting figure by the efficiency of the inverter (approximately 90%). As a result, the maximum power will be equal to: 160x25/0.9=4444 W.

After making the calculations, you can begin to select an electric generator. In this case, you should focus on the maximum power consumption, adding a reserve of 25% to it, so as not to use the power plant to its maximum capacity. Therefore, for a welding inverter with an operating current of 160 A, you need to buy a generator with an output power of at least: 4444+4444x0.25=5555 W, or 5.5 kW.

Gasoline generator or electric generator?

Connection diagram of the inverter to the battery.

In some cases, if it is impossible to use an external power supply, welders try to connect inverter welding through a low-power gas generator. This approach is incorrect if its power is less than 5 kW. The operating voltage in such generators strongly depends on the load size. Inverter devices are sensitive to voltage changes, so if the output voltage of the gas generator changes frequently, the welding machine may fail.

When welding with a 3 mm electrode, the operating current reaches 120 A at a voltage of 40 V. In this case, the output power will be: 120x40 = 4800 W, or 4.8 kW, that is, the gas generator will operate at maximum power, which will also lead to its premature exit building. Therefore, if the network is poor, it is better to connect the welding machine to an electric generator.

Selecting a cable to connect the inverter

To carry out high-quality welding, it is very important to choose the right connecting wires. Welding wires are selected according to the following indicators:

Functionality of the welding inverter.

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

The inverter cable is a flexible current conductor with good insulation. In most cases, such a wire is made of copper wires 0.18-0.2 mm thick, woven together. Such cables are used to connect the inverter to the electrical holder, as well as to ground the device. The choice of wires depends on their technical characteristics and the characteristics of the welding unit itself.

Among welders, the most popular is the KG brand wire (Fig. 1). Manufacturers of this type of cable recommend its use in alternating current circuits with a voltage of no more than 600 V or in direct current circuits with a voltage of no more than 1000 V.

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

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

In addition to the KG brand, KOG1 brand wire is also used, which is more flexible than the first option. It is used in cases where the welder needs to constantly move to perform work.

Connecting the welding cable is carried out taking into account certain rules:

1. Connections should be made using pressed or soldered lugs.
2. The cable is connected to the power connectors of the unit (+) and to the electrode holder in reverse polarity (-). The polarity can only be changed when the current parameters are changed.
3. When carrying out welding work, the welder is prohibited from pulling the inverter towards himself with wires.
4. Under no circumstances should the rated power of the cable be exceeded.

Connecting welding inverters using extension cords

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

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

Do-it-yourself welding of copper and aluminum wires

The provisions of the PUE recommend welding of wires as one of the most reliable methods of connecting them. The advantages of using this method significantly outweigh the few disadvantages, which makes it popular among home craftsmen and professional electricians.

Pros and cons of welding, its varieties

The advantages of connecting wires by welding are the absence of transition resistance, which is always present in twisted or bolted connections. This is especially true when laying wiring for powerful devices.

https://www.youtube.com/watch?v=SmWukRgOebY

The disadvantages are the need to buy or make your own welding machine designed for twisting.

Welding work requires some skills, so the electrician who will weld the strands needs to learn at least the basics of this craft.

When performing electrical installation work in production, various types of welding are used: standard, arc spot, plasma, torsion, electron beam, ultrasonic, or various combinations thereof. For domestic use, electricians most often use a device for spot and arc welding, which operates on carbon or graphite electrodes.

This solution allows you to obtain good quality connections at a minimum cost of the necessary devices and components.

When making a wire welding machine, most attention should be paid to the following characteristics of the device:

• The current strength that the device can produce. Ideally this is a variable value.
• The voltage produced by the device is sufficient to cause an electric arc - usually 12-32 Volts.
• What kind of current does the welder use - alternating or direct? If you have experience in such work, you can use variable, but for beginners it is strongly recommended to start with constant.

Since welding different metals requires different currents and voltages, universal welding machines can necessarily adjust these values.

In addition, when joining different materials, you may need special fluxes that will protect the metal from oxidation or the penetration of gases from the air into it.

Most universal-purpose welding machines are quite bulky and heavy, but for small welding jobs you can find inverter welders for a relatively low price that are ideal for welding wires.

If you are welding copper wires that are used in home wiring, there is no need to use very high current and voltage, so it is possible to use small-sized welding machines that fit into a standard tool case.

The principle of operation of arc welding - device diagram

Since welding requires a large current, the basis of any welding machine is a step-down transformer - a loss in voltage is always accompanied by a gain in current and vice versa.

A standard diode bridge is used to convert alternating current into direct current, and a capacitor is used to smooth out ripples.

A noticeable disadvantage of using a direct current device is that the diodes and capacitor used are rather large and they significantly increase the weight of the welding machine, which is initially made portable.

Experts also recommend installing additional resistance at the input or output of the diode bridge, since diodes “do not like” a short circuit in its pure form.

Many craftsmen manually assemble a welding machine for welding copper wires, which produces an arc from alternating current and use them successfully. Therefore, it is impossible to say unequivocally that it is necessary to use a direct current device - everyone chooses the necessary model according to their skills. If an AC welding machine is manually assembled, then the diode bridge and capacitor are simply thrown out of the circuit.

A necessary skill that you will have to master to use an AC welding machine is to learn “by eye” to determine how long you should hold the ignited arc of the electric discharge so that the end of the twist heats up and fusions.

The most common way to make a negative contact for welding is with old pliers that hold the wires.

For the phase, take a clamp that can hold the graphite rod. The design of the clamp can be very diverse - from a screw connection to the so-called “crocodiles”, both home-made and factory-made. To connect to the welding machine itself, cables with a cross-section of about 10 mm² are used.

Despite the fact that a device assembled in an industrial environment is an order of magnitude more expensive than a homemade one, its price is not exorbitant and allows you to purchase such a welding machine even on a limited budget. The advantages of its use are obvious - it is a precisely calculated design with a current regulator, which allows you to work with different types of metals and the number of wires being welded.

Nuances of the wire welding process

With the necessary skills, welding conductors does not take much time, but in order to obtain a high-quality connection, it is strongly recommended that you first practice on separate pieces of cables. Moreover, this must be done if you are using a twist welding machine that works with alternating current - you need to get used to the power of such a device. The whole process is clearly shown in the following video:

Step by step everything looks like this:

• Stripping wires. A feature of welding is the need to expose the wire cores to a length of 60-80 mm. Less is impossible, since during welding the wire heats up quite strongly and the insulation will melt.
• Twisting wires. It would seem that you can simply fold the wires and weld - a drop will still form at the end, which will connect everything together. The problem with this connection method may be the fragility of the wires - it is not a fact that it will occur, but for some reasons, the droplet resulting from welding with a carbon electrode acquires a spongy structure and is susceptible to fracture. This does not affect conductivity, but if the wires are not twisted, they may break.

• Trimming the twist. The fluffy ends of the veins must be trimmed to get an even cut. Then the arc during welding will evenly heat the entire surface of the twist and the drop will be even.

• Welding. The twist is grabbed with pliers and a graphite electrode is brought to its tip until an electric arc occurs. It must be maintained until the ends of the wires fuse, forming a smooth drop. The next twist is welded after the previous one has cooled.

If the arc does not appear, then the power of the transformer is insufficient or the wires to the electrode holders are too long (their resistance prevents sufficient current from being obtained).

The optimal option for the length of the wires is 2.5-3.5 meters, but in the first case you will have to place the welding machine on a stand for ease of operation.

• Twist insulation. The best option in terms of speed here would be to use heat-shrinkable casings, but to warm them up you will additionally need a hair dryer or a good lighter. There is also no hindrance to using ordinary electrical tape - except that it will take a little longer.
• Welding copper and aluminum wires. In general, it is performed in exactly the same way as a regular one - the only difference is in the preparation of the wires. The copper core remains straight, and the aluminum core is wrapped around it. Then flux is applied to the aluminum, which, when heated, removes the oxide film from this metal, and welding can begin.

But if you follow the instructions of the PUE, then in domestic conditions you are unlikely to have to work with aluminum wires, since the use of such cables with a cross-section of less than 16 mm² is prohibited for laying electrical wiring.

Welding wires with an inverter

The use of such a device is most preferable, since welding copper and aluminum wires with an inverter is much easier than with homemade welding machines. This is a universal device, the current in which is adjustable in the range of up to 160 Amperes. In addition to the fact that it can weld twists, it allows you to work with metal up to 5 mm thick - for home use this power is usually more than enough.

Typically, such a device is the prerogative of professionals who are constantly faced with welding work, but at the same time it can be safely recommended to beginners who are just mastering welding strands with their own hands. The “hot start” function, protection against electrode sticking and the ability to work even during voltage surges will allow a novice welder to quickly master the basics of this craft, and a professional will always enjoy working with a good tool.

If the device allows you to regulate the voltage and current, then “by eye” what values ​​to set can be determined by the diameter of the wires and their number.

Briefly about the main thing

Welding the ends of twisted wires significantly improves the conductivity of these contacts, and therefore the characteristics of the network as a whole.

Welding machines that allow spot welding are commercially available and are also simple enough in design to make them yourself. But in the second case, simpler devices that produce alternating current are most often assembled - such devices require certain operating skills.

In practice, there is not much difference in using one device or another - if the master is experienced enough, the result will be good in any case.

Source: https://YaElectrik.ru/elektroprovodka/svarka-provodov

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

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

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

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

Cable requirements for a welder

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

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

It follows that the cable must meet the following requirements:

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

Suitable cable brands and types

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

The title may also contain a note about the performance:

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

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

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

Selection of section and length

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

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

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

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

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

Cable for connecting the welder to the network

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

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

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

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

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

Operating rules

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

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

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

Rules for welding copper wires

One of the common causes of fires is faulty electrical wiring. Fires occur due to insulation failure or heating of cable cores at connection points (sockets, switches or junction boxes).

Poor contact leads to the appearance of a large contact resistance, which generates heat. This destroys the insulation, causing a short circuit and fire.

Therefore, obtaining a reliable, high-quality connection of copper conductors is a prerequisite for the safe operation of any household electrical appliances.

Using an inverter

Copper wires, most common in residential buildings, are connected in several ways, but welding is considered the most reliable. As a result of this connection, a homogeneous conductor is obtained, which ensures complete fire safety.

Welding is carried out with direct or alternating current voltage from 12 to 36 V, and the welding current must be adjusted. Most welding inverters meet these requirements.

They produce a special apparatus for welding copper wires, which is used by electricians. It has a power range of 1-1.5 kW and welding current adjustment in the range from 30 to 120 A.

Unlike conventional inverters, the equipment has less weight and dimensions; in addition, the ends of the welding cables are equipped with a special holder for carbon electrodes and a clamp with a large clamping surface for the conductors.

If the farm already has an inverter welding machine, then you don’t need to buy a special device for welding copper wire.

For convenience, pliers and an electrode holder are welded to the welding cables or attached through a bolted connection. Any powerful clamp can play the role of a carbon electrode holder. Its handles must first be insulated.

The pliers are attached to the ground wire. They will hold onto the twist of the copper conductors being welded, while they will perform the important function of heat removal. This is necessary to protect the insulation from exposure to high temperatures.

Contact method

In addition to using an inverter for welding copper wires, spot contact welding can also be used, the welding time of which does not exceed 1-2 seconds.

At home, to connect household electrical wiring, you can use a conventional 500 W transformer with a voltage in the secondary winding of 12-36 V. By attaching a holder for the electrode and copper wires to the secondary winding, we get a simple welding machine.

Depending on the cross-section and number of copper wires, it has been experimentally established that the current for welding should be:

• for 2 wires with a cross section of 1.5 mm2 – 70 A;
• 3 sections 1.5 mm2 – 80 A;
• 3 sections 2.5 mm2 – 90-100 A;
• 4 cross-section 2.5 mm2 – 100-120 A.

However, current values ​​can vary greatly depending on the cable used and its manufacturer. The fact is that cable manufacturers use copper wires with various impurities, which affects electrical and thermal conductivity; wire cross-sections sometimes do not correspond to the declared characteristics.

Therefore, spot welding is carried out only after the optimal welding current has been adjusted on scraps of the same cable that is to be welded.

Procedure

When welding wires with your own hands, the procedure will be as follows. First, you need to remove the insulation from the ends of the conductors to be welded to a distance of 8-10 cm.

When removing insulation, do not damage the wire cores. Before twisting, they must be cleaned with sandpaper and wiped with acetone to degrease.

Then the copper wires to be connected are twisted and the ends are cut with wire cutters so that the end of the twist is flat. The result should be a bunch about 5 cm long.

The preparatory work ends here, and the welding itself begins. The ground clamp of the turned on welding machine is attached to the twist, and a graphite or carbon electrode is brought to the end of the twisted conductors, which is held at the end of the second welding wire using a special holder.

As a result, a short circuit occurs with the formation of an electric arc. Its energy is enough to melt the ends of copper conductors in 1-2 seconds.

A molten drop of copper forms at the end of the twist; it needs to be given time to cool. After this, the twisted area is insulated with tape or heat-shrink tube (the tube must be put on in advance).

The welding joint is of high quality; its electrical characteristics do not differ from those of the entire copper wire, and will last no less than it.

Process Features

Welding copper wires has its own characteristics. This is due to the fact that at a temperature of 300 °C copper becomes brittle, and at 1080 °C it melts.

The electrodes can withstand temperatures three times higher. Therefore, it is important not to overexpose the arc, so as not to damage the insulation and the wires themselves.

To protect them, you need to connect a powerful radiator in the twisting area, preferably made of copper with a large heat transfer surface and tight pressure to the twist, and then only weld.

When welding copper wires, it is advisable to place the twist vertically. In this case, the molten drop will take on a spherical shape, which will cover all the wires being welded.

Sometimes it is necessary to weld not single-core, but multi-core copper wires. In this case, you must first place the twist in the sleeve, crimp it, cut off the protruding end and then weld it.

Electrodes used

To weld copper wires, carbon or graphite electrodes with copper plating are used. Their characteristics are almost the same.

They have a melting point three times higher than that of copper, due to this, electrode consumption is minimal; are easy to cut, which allows you to obtain a length convenient for welding.

Carbon electrodes produce an arc of higher temperature than graphite electrodes, which allows them to be used at minimal welding currents. They are also convenient when using homemade low-power welding machines.

Welding with graphite electrodes is often used with inverters that have current control over a wide range and are undemanding to the welder’s qualifications. In addition, the copper welded joint is of higher quality.

Externally, the electrodes differ in color - coal black, and graphite dark gray with a metallic tint.

If you don’t have factory electrodes at hand, then when welding they can easily be replaced by brushes from an electric motor or a carbon rod from an old battery.

Source: https://svaring.com/welding/detali/svarka-mednyh-provodov

Cable for welding machine - review of brands, comparison, buying tips

There are often situations when it is necessary to replace the old welding cable with a new one, or the welding cable that came with the inverter was too short or of poor quality. For example, owners of a Resanta welding machine note that copper-plated cables are often included in the kit.

The most popular cable for welding is a power cable of the KG brand, which stands for K - cable G-flexible.

Power cable KOG1 is the second most popular welding cable; it is used when it is necessary to carry out welding work in hard-to-reach places. KOG stands for cable of special flexibility.

You may also come across an offer to buy a welding cable of the KRPT brand, which stands for portable rubber cable. However, it is worth knowing that this brand has been discontinued and today the closest analogue is the KG cable

The KGN and KG-HL brands are no different in appearance from the KG cable. However, the KGN sheath is made of oil- and gasoline-resistant rubber based on butadiene rubber, which protects the cable from sparks, oils, and gasoline.

You will only need KG-HL for welding to carry out work in extreme conditions at temperatures below -40 C. The KG-HL cable is designed for operation from – 60 to + 60 degrees.

In addition to the widely used welding cables KG and KOG, there are other brands of cables for electric welding equipment, such as KPES, KVS.

The KPES brand belongs to the hollow type of cable, that is, there are no cores in such a cable; instead, a round metal tube is used. KPES is designed to supply electrodes to the welding site and to supply current 42V/48V AC/DC voltage; the cable is used for automatic and semi-automatic arc welding, including submerged arc welding.

You can work with such a cable at a temperature not lower than – 10 C. The cable has a fairly short service life depending on the diameter of the channel, for example, with a channel diameter of more than 3 mm, the service life is at least 3 months, with a channel diameter of more than 6 mm - at least 1 month. 5 years. The cable manufacturer is TD "Ukrkabel".

In addition to welding work, it is used for connecting electric furnaces.

Cable for welding equipment KPES

The KVS brand stands for PVC-insulated welding cable. Used to connect the welding machine holder to a power source up to 127/220V AC/DC voltage. KVS operating temperatures range from minus 40 to plus 40 degrees. Since KVS uses polyvinyl chloride insulation, it does not have the same flexibility as the KG cable.

You can buy a cable for a welding machine

Difference between welding cable KG and KOG1

Visually, the design of the single-core welding cable KG and KOG1 is similar and there would seem to be no difference between them:

1. Stranded copper core, i.e. consisting of individual wires.

2. Synthetic film over the core (visually similar to polyethylene, cellophane). 

3. Rubber insulation

4. Rubber shell

In the KOG1 cable it is possible to apply a common insulating and protective sheath with a greater thickness (at least 2-3 mm)

Nevertheless, there are differences between the welding cables KG and KOG1 and they are quite significant:

1. Flexibility class

   Welding cable KG has the 5th class of flexibility, and KOG1 – the 6th. What does it mean? This means that the diameter of grade 6 wires is thinner than grade 5. For example, in KG 1x16 the diameter of the core wires is 0.41 mm in accordance with GOST 22483-77, and in KOG1 1x16 it is 0.21 mm, so KOG1 1x16 is more flexible and softer. In this regard, KOG1 has a smaller minimum bending radius, which means that it can be bent more at the angle you need.

   IMPORTANT!

   The KOG1 cable is more flexible compared to the KG cable

2. Cable weight

   The weight of 1 m of cable KOG 1x16 is 240 g, the weight of KG 1x16 is 310 g. The longer you choose the welding cable, the heavier it is. Taking into account that the length of the welding cable can reach 40 m, the difference will be several kilograms.

3. Different voltage settings

   The KG cable is rated up to 660 V at an alternating current voltage (up to 400 Hz) volts, and the KOG cable is rated up to 220 volts and 50 Hz.

Recommendations when purchasing a welding cable

1. The cable must have a copper stranded core. You may find a Chinese KG cable on the market, in the core of which the copper content will be no more than 60-70%; the color of such copper is noticeably duller. Conclusion, buy CG from trusted suppliers who have certificates for their products.

Welding machine power cable

 To power the welding machine, it is also necessary to use cables and wires for movable installation, since the inverter still has to be moved during operation. The same cable KG or PVS is suitable as such brands. The same brands are suitable as an extension cord for a welding machine.

The recommended cross-section is not less than 2.5 mm2 with a length of no more than 20 m. In any case, the cross-section of the power cable for the welding machine must be selected depending on the rating of the source machine in order to protect the cable from overload.

It is also necessary to take into account voltage losses if the cable is long enough (more than 20m).

Welding machine grounding cable

Welding machines powered through flexible cables or having a permanent power connection usually have a separate ground wire. For stationary welding equipment, usually the grounding cable is attached at one end to the body of the device and at the other to a metal rod in the ground. Thanks to this, equality of potential is created, and even if the body of the device is energized, an electric shock will not occur upon contact.

A cable with copper conductors with a cross-section of at least 6 mm2 is used as a cable for grounding the welding machine. Brands PV6-3, PUGV and others can be used as a grounding cable.

Source: https://elmarts.ru/blog/sovety-pokupatelyam/kabel-dlya-svarochnogo-apparata/