Welding equipment needs to be connected correctly in order to perform properly. The wiring must be properly sized for the current level required and the breaker should be able to handle the amount of current that is being drawn by the equipment. The proper connection also ensures that the wiring is not exposed to excessive heat, which could damage the wire or cause a fire.
Welders are designed for specific types of welding processes and are equipped with a variety of features to make them easier to use. They are capable of generating power and heat to weld metals of various sizes, shapes and thicknesses. Welders are used for a wide range of industrial applications, from construction to transportation.
Before hooking up a welding machine to any type of electrical outlet it is essential to understand how the welder works and what its limitations are. This will allow you to avoid accidents and improve your productivity levels.
Circuit breakers and a voltage source
When you purchase your welder it should come with a circuit breaker and the appropriate wiring for the volts it requires. The breaker is a safety device that will trip and shut off the current if there is an overload or short by your welder. Generally, 220-volt welders require a 50-amp circuit breaker, while 110-volt welders need a 30-amp breaker.
Wires should be sized for the maximum input current of your welder and should be properly rated (either AWG or kcmil). Welding cable is a flexible copper strand that is surrounded with an insulating jacket to resist flame, oil, abrasion, and heat. The insulating jacket is made of a durable, non-conductive material that can hold up to repeated movement over rough surfaces and prevent damage from weld splatter and burns.
Selecting the correct size of welding cable is a very important decision as it determines how efficiently the welder will operate and can affect productivity. There are charts available that show what cables are needed for various voltage and current settings, but you should always read your owner’s manual before making a purchase.
Fraying or ripping of the cable’s insulation and strands can also lead to an inability to carry enough current without overheating. This can happen for several reasons, such as bending the cable back and forth or using a lug that is too large to fit onto the welder’s output studs.
A loose connection between the work or electrode wire and a welding gun’s output lug is a major cause of poor welds. This is because a lug can slip or come loose and cause an erratic arc. It can even overheat and fuse if it is too loose.
Choosing the correct shielding gas for your welding process is another factor that is essential to good welds. A high ratio of Argon in the shielding gas is preferred as it provides the best protection and creates the optimum environment for welding.
Loose connections to the work or electrode wire are a major cause of bad welds and should be repaired immediately. The lugs that attach to the wires should be tightened and the contact tips should be cleaned before use. The O-rings that connect the lug to the work or electrode wire should also be replaced as they can become worn and lose their ability to keep the connection tight.
