Clarke 105TEN - wire speed on 0.9mm zintec

[jb2000]

Size makes a big difference with thin metal and low amps, most of the low end welders are near their minimum limit re sensitivity analysis.

 

[jb2000]

Oops, speed was 4.0 exactly, power was "1"+"Min", 0.9mm Gasless Clarke, 105TEN. Just as a data point.

 

[jb2000]

Now trying with an extension lead...

2 practice butt-joints, 0.80mm steel, Clarke 105TEN, Clarke gasless 0.9mm wire, power "1"+"Min". Benefit of wire-brush or clean-n-strip-disc to remove gasless slag very obvious between welds.

#1 - No extension lead, wire speed "4.0".
Very easy to get great penetration tacks and 1cm bead joining.

#2 - 25m 2.5mm^2 H07RNF extension lead, wire speed "4.0".
Sizzle noticeably muted, fierceness gone, noticeably less penetration, 1cm beads only minimal penetration to the rear rather than "as much below as above".

Trying wire speed "4.5" brought penetration back up.

Surprising really.
I guess I now know why welders pounce on 25m of 6-10mm^2 H07RNF BS4343 extension leads. Voltage drop vs current draw counts a lot.

My supply is not particularly high impedance - PSSC L-N & PFC L-E are 2100-2700A with PME supply (TN-C-S), supply cable is underground PILC. Those figures are pretty typical for the UK re what a DNO aims for to guarantee instant fault disconnect on a 60/80/100A BS1361 cutout fuse.

A Kemppi 180 by virtue of being an inverter would not care about the extension lead, can see why contractors like them (apart from the price).

 

[jb2000]

Some pictures with comments...

#1
0.8mm sheet, Clarke 105TEN, Clarke 0.9mm Gasless wire, Power "1"+"Min", Speed "4.0".
No extension lead.

#2
0.8mm sheet, Clarke 105TEN, Clarke 0.9mm Gasless wire, Power "1"+"Min", Speed "4.0".
25m extension lead.

#3
0.8mm sheet, Clarke 105TEN, Clarke 0.9mm Gasless wire, Power "1"+"Min", Speed "4.5".
25m extension lead.

The difference is noticeable, auditory too.