[RE-wrenches] Fwd: Re: DC arc welder?

Ray Walters ray at solarray.com
Sat Nov 23 12:53:11 PST 2013


Leave it to Windy to be about a generation ahead of the rest of us on 
all things RE once again. Cheers to Windy:-)

I still own a Battery Weld 2000 from the 90s, which is a MIG machine 
that runs on 24 v dc.   The limit is the battery.  It can blast at over 
200 amps, if you have enough battery to keep the voltage up.  I used to 
run a 18 v golf cart battery string, so I wouldn't have to use the on 
board resistor bank for lower amp welding.  My DC welds start getting 
messy about 12" into the weld, as the battery voltage drops and changes 
the equation.
If you're doing a lot of welding, I would use an AC machine and 
inverter, as its much better controlled.  Just this week, I tested a 
Magnum 4024 PAE with my Lincoln 180, 240 vac MIG machine.  The inverter 
could handle it, but once again the batteries were the limit, and my 
experiment did not have enough battery behind it to keep the inverter on 
for very long.  4 Golf cart batteries would be the minimum.
My local industrial battery company has a carbon rod setup, and they 
short the battery to weld the lead connectors to the battery posts.  
That's the preferred method for adding or removing lead connections at 
the battery posts, although I'm not sure if OSHA would approve. They 
open all the battery caps, so that they don't build up too much hydrogen 
to explode....Sketchy?

R.Ray Walters
CTO, Solarray, Inc
Nabcep Certified PV Installer,
Licensed Master Electrician
Solar Design Engineer
303 505-8760

On 11/23/2013 11:38 AM, Allan Sindelar wrote:
> Forwarding from Windy.
>
> -------- Original Message --------
>
> Sure you can solar weld! Afterall, some of us have welded from battery 
> power when we preferred NOT to.
>
>    :0)     <<  that's the HONK of a Solar Bozo (Emeritus)
>
> But seriously, Back in the 1930's to 50's when thousands of farms and 
> ranches had wind power, 32V was the standard voltage for the 2-3kW 
> systems. Among the many tools and appliances available, it was common 
> to have a 32V welder. I used one of them back in the 70's. I was 
> nothing but a box with a coil in it. The coil wasn't for inductance, 
> just for resistance. It was steel wire maybe 1/8" thick with taps to 
> give a choice of current. For max. current, the coil would be 
> completely out of circuit.
>
> The guys I shared the shop with abandoned their buzz box 'cuz the DC 
> was so smooth.
>
> Towers are still standing on welds I did in the late 70's using 6011 
> and 7013 rod (if I remember right).
>
> I had a cell failure early on, and my system was 30, not 32V. Worked 
> fine for years.
>
> I'm quite sure 24V would work, at least for smallest rods. It 
> certainly works for MIG welding. Century made a 24V "Portable MIG" to 
> use on 24V diesel vehicles and farm machines for field repairs. They 
> were made in 70's and 80's. Nice, 'cuz they are light-weight / no 
> transformer. I used one on my PV system until I moved recently. I had 
> 3-4V of line loss and it still worked fine with .030 wire. Again, it 
> has steel coils with taps for control.
>
> If you want MIG, search for a Century Portable MIG. Otherwise, get the 
> smallest sticks and try 24V. I think I tried it, or heard that it's 
> not quite enough V. 36V is MORE than you need. If you do 36, use 
> undersized cable because you'll need resistance anyway!
>
> Searching ... 24V MIG is in remote storage with hen's teeth and 
> unobtainium.
> but discussion at
> http://forum.ih8mud.com/tools-fabrication/416445-snap-24v-portable-mig.html
> confirmed that you can do stick with 24V.
> AND somebody suggested this:
> http://store.cyberweld.com/twsgspgun10.html
>
> The spool gun looks like the modern way to solve the problem for 
> professional use. Reviews there say it doesn't have speed control on 
> the gun. So you need a resistance coil with taps, and you need a speed 
> control.
>
> I hope this helps!
> Windy
>
> Windy Dankoff    Solar Bozo Emeritus
>
>   Specialist in solar-electric applications & solar water pumping
>   Education   <>   Industry support   <>    Since 1975
>   ---------------------------------
>    Founder, retired, Dankoff Solar Products, Inc.
>       spin-offs:  Dankoff Solar Pumps  .  Positive Energy  .  Conergy USA
>    Co-author, work in progress: _The Handbook of Solar Water Pumping_
> _
> _
> 12-minute TV interview:
> http://www.youtube.com/watch?v=yt3hKgriSbo&list=TLrXFKMLwzCwuUD5h52WCzKdWRR-Juk3XA
>   ---------------------------------
> windydankoff at mac.com <mailto:windydankoff at mac.com>
>    Santa Fe, NM
>    home (505) 466-4280
>        cell (505) 490-0313
>
>
>
>
>
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