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Spot welding going wrong (again)
#1
Hello all,

Cause of some videos on YT I'm now way over enthusiastic about this DIY powerwall thing. It has costed me tons of time to watch them all. Besides that I'm afraid I got infected with this battery virus thing. I don't want to mention the guilty for this all but there names start with H, D and A and they end with HBPowerwall, DIYtechandrepair and Average Joe.

So I bought a spotwelder on Ali to start practicing my skills but it doesn't work as it should. It makes a few (4 to 6 or so) welds and then the next one gives a big bang with spark and all and the fuse trips. When I try immediately after resetting the fuse it will trip again but when I try next day I can do a few welds again before fuse trips. What can this be?

This is the welder I purchased:

Spot welder

I asked the supplier and he just answered to put a 40A fuse which is easier said than done cause the main fuses in my house are only 25A and the subsequent is 16A. Here in the Netherlands, we have 230V mains so the man is telling me I should fuse for a burst of 40 x 230 = 9.3 kW which sounds ridiculous to me.

What are your thoughts on this?

Rik
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#2
It looks like you bought a cheap welder that doesn't even have a brand name. I would return it and buy either a Sunkko 709AD (220 version) or a Kweld. It is normal for the welder to draw a high instantaneous current, but there's no way it should require a 40A breaker... I have 15A fuses on my Sunkko and have done tens of thousands of welds without ever blowing a fuse.
Korishan likes this post
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#3
I agree with mike. It shouldn't be popping the breaker/fuse like that. Something is wrong with it. I wonder if the transformer is wound properly with the correct winding count.

At that price range, I think you can get the same type of welder Peter/Joe use. But the Kweld is also a good option and it'll run off of your DC power supply (whether thats solar generated battery stored, or power supply)
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#4
Hi Mike,

Tnx for your response. I was afraid for this answer already, I should'n have bought it. I was already looking at the 709AD but there is also a 709AD+ version. Would that one be better?

Rik

Korishan tnx for your advice. Can the Kweld be bought complete or do you have to make it yourself? I prefer an out of the box working solution. Do you have a link to the Kweld?

Regards, Rik
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#5
(01-03-2019, 09:15 AM)RikH Wrote: I asked the supplier and he just answered to put a 40A fuse which is easier said than done cause the main fuses in my house are only 25A and the subsequent is 16A. Here in the Netherlands we have 230V mains so the man is telling me I should fuse for a burst of 40 x 230 = 9.3 kW which sounds ridiculous to me.

What are your thoughts on this?

The supplier is correct, the power requirement is one of the few specifications listed in that link you posted.

Can you confirm that your property is limited to a total instantaneous demand of 25A or is that simply the fusing on the circuit the welder is connected to ?

25A for an entire house is very low.
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#6
Hi Sean,

Yes the average household connection over here 3 x 25A. After this fuses comes the meter, all sealed. AFter this you have your own fuse for several groups in the house wich are fused 16A. 16 x 230 = 3,6 kW. When you need more you need 3 phase equipment but thats not what this welder is. But you're right it is stated clear that it is 10 kVA.

So if anyone can use this thing give me a pm.

Ciao, Rik
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#7
3x 25A sounds more useful - but not for 1ph spot welders :-(

If you've got a good quality 25m mains extension cable (or longer) you might have some joy plugging your welder into that.
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#8
(01-03-2019, 02:46 PM)RikH Wrote: Hi Sean,

Yes the average household connection over here 3 x 25A. After this fuses comes the meter, all sealed. AFter this you have your own fuse for several groups in the house wich are fused 16A. 16 x 230 = 3,6 kW. When you need more you need 3 phase equipment but thats not what this welder is. But you're right it is stated clear that it is 10 kVA.

So if anyone can use this thing give me a pm.

Ciao, Rik

hello rik.

i find it hard to believe that you need that kind of power.
i think for now you have two options 

1 ) check your automatic breaker , is it a 16A B  then you can change it for a 16A C , the C breaker can withstand a higher inrush current , mostly used when you use heavy equipment like grinders , welders etc..

2 ) when you are good in electronics you could check how the welder is build up and maybe you could change the active element by a solid state relais , the most have a zero crossing function , this is a much better switching and can prevent the tripping of the breaker.
i have build myself a spotwelder and a 1000 Watt microwave transformer in conjunction with a ssr and i have no troubles what so ever

also the tip from sean : If you've got a good quality 25m mains extension cable (or longer) you might have some joy plugging your welder into that , it works like a gigant inductor and so this could be the solution
that would work for you
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#9
Before you buy another welder, replace those probe cables, they look like copper clad audio wire. You need to get 6 gauge pure copper welding cable (you can get about 3 feet black/red cable on ebay for less then 20 dollars. 

With pure copper you can reduce the power setting on your welder. If the setting is too high you be blowing fuses and the cheap copper clad cable will be getting hot. I would try that before spending 200 dollars on another welder, which might keep blowing fuses.

My advice since you might have problems with your house current is to buy a battery powered welder, the malectrics cost 100 dollars and is rock solid, you can run it off a 12 volt car battery or even a 3s lipo battery pack. I build many packs with one of them.

I got the first version they sold, below is a picture of their version 3 which is a big improvement but the old version worked great also. This welder fits in the palm of your hand but is comparable in power to any of the plug in models. I weld in power setting 3 and it goes all the way to 9. 
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#10
Ok, I decided to go this way: try a long extension cable and if that doesn't work I'll buy the welder jonyjoe505 pointed me to:

Malelectrics

Leipi35 tnx for your kind advice in changing fuses, cables etc but I don't want to to to much time and effort in this. Tnx to all so far, I'll let you know if the test with the extension cable will solve it.
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