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</o:shapelayout></xml><![endif]--></head><body bgcolor=white lang=EN-US link=blue vlink=purple><div class=WordSection1><p class=MsoNormal><span style='font-size:18.0pt;font-family:"Arial Black","sans-serif";color:black'>I used to use a wire feed welder built off a custom GM “SI” series alternator, it would put out 160 amps at full tilt boogie. I also used the same alternator to charge my house batteries off a Honda 9hp engine when I needed to get in a boost occasionally. Around here in the winter that is far too often!<o:p></o:p></span></p><p class=MsoNormal><span style='font-size:18.0pt;font-family:"Arial Black","sans-serif";color:black'><o:p> </o:p></span></p><p class=MsoNormal><span style='font-size:18.0pt;font-family:"Arial Black","sans-serif";color:black'>As far as welding on industrial batteries, that is how it is done, When I am working on large packs that’s how you install the straps as well as changing cells or rebuilding posts in the field. <o:p></o:p></span></p><p class=MsoNormal><span style='font-size:18.0pt;font-family:"Arial Black","sans-serif";color:black'><o:p> </o:p></span></p><p class=MsoNormal><span style='font-size:18.0pt;font-family:"Arial Black","sans-serif";color:black'>Do you want to clear a room fast? Fire up a torch and walk over to a 40 cell bank, the room clears, Like NOW! <o:p></o:p></span></p><p class=MsoNormal><span style='font-size:18.0pt;font-family:"Arial Black","sans-serif";color:black'>That’s fine, you don’t want them in there bothering you while you are working anyway!<o:p></o:p></span></p><p class=MsoNormal><span style='font-size:18.0pt;font-family:"Arial Black","sans-serif";color:black'><o:p> </o:p></span></p><p class=MsoNormal><span style='font-size:18.0pt;font-family:"Arial Black","sans-serif";color:black'>As a safety tip, you remove all the cell caps and fill each cell with oxygen displacing any stray hydrogen. I use oxygen and propane for the actual weld. It burns cleaner than acetylene and the less trash you get into the molten lead the better for the connection. <o:p></o:p></span></p><p class=MsoNormal><span style='font-size:18.0pt;font-family:"Arial Black","sans-serif";color:black'><o:p> </o:p></span></p><p class=MsoNormal><span style='font-size:18.0pt;font-family:"Arial Black","sans-serif";color:black'>That is how it is done.<o:p></o:p></span></p><p class=MsoNormal><span style='font-size:18.0pt;font-family:"Arial Black","sans-serif";color:black'>Quick Cable has some good videos on their web site showing the process.<o:p></o:p></span></p><p class=MsoNormal><span style='font-size:18.0pt;font-family:"Arial Black","sans-serif";color:black'><o:p> </o:p></span></p><p class=MsoNormal><span style='font-size:18.0pt;font-family:"Arial Black","sans-serif";color:black'>Later,<o:p></o:p></span></p><p class=MsoNormal><span style='font-size:18.0pt;font-family:"Arial Black","sans-serif";color:black'>Bob Ellison<o:p></o:p></span></p><p class=MsoNormal><span style='font-size:18.0pt;font-family:"Arial Black","sans-serif";color:black'><o:p> </o:p></span></p><div><div style='border:none;border-top:solid #B5C4DF 1.0pt;padding:3.0pt 0in 0in 0in'><p class=MsoNormal><b><span style='font-size:10.0pt;font-family:"Tahoma","sans-serif";color:windowtext'>From:</span></b><span style='font-size:10.0pt;font-family:"Tahoma","sans-serif";color:windowtext'> re-wrenches-bounces@lists.re-wrenches.org [mailto:re-wrenches-bounces@lists.re-wrenches.org] <b>On Behalf Of </b>Ray Walters<br><b>Sent:</b> Saturday, November 23, 2013 3:53 PM<br><b>To:</b> RE-wrenches<br><b>Subject:</b> Re: [RE-wrenches] Fwd: Re: DC arc welder?<o:p></o:p></span></p></div></div><p class=MsoNormal><o:p> </o:p></p><div><p class=MsoNormal>Leave it to Windy to be about a generation ahead of the rest of us on all things RE once again. Cheers to Windy<span class=moz-smiley-s1> :-) </span><br><br>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. <br>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.<br>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? <br><br><o:p></o:p></p><pre>R.Ray Walters<o:p></o:p></pre><pre>CTO, Solarray, Inc<o:p></o:p></pre><pre>Nabcep Certified PV Installer, <o:p></o:p></pre><pre>Licensed Master Electrician<o:p></o:p></pre><pre>Solar Design Engineer<o:p></o:p></pre><pre>303 505-8760<o:p></o:p></pre><p class=MsoNormal>On 11/23/2013 11:38 AM, Allan Sindelar wrote:<o:p></o:p></p></div><blockquote style='margin-top:5.0pt;margin-bottom:5.0pt'><p class=MsoNormal>Forwarding from Windy.<o:p></o:p></p><div><p class=MsoNormal><br>-------- Original Message --------<br><br>Sure you can solar weld! Afterall, some of us have welded from battery power when we preferred NOT to. <o:p></o:p></p><div><p class=MsoNormal><o:p> </o:p></p></div><div><p class=MsoNormal> :0) << that's the HONK of a Solar Bozo (Emeritus)<o:p></o:p></p></div><div><p class=MsoNormal><o:p> </o:p></p></div><div><p class=MsoNormal>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.<o:p></o:p></p></div><div><p class=MsoNormal><o:p> </o:p></p></div><div><p class=MsoNormal>The guys I shared the shop with abandoned their buzz box 'cuz the DC was so smooth.<o:p></o:p></p></div><div><p class=MsoNormal><o:p> </o:p></p></div><div><p class=MsoNormal>Towers are still standing on welds I did in the late 70's using 6011 and 7013 rod (if I remember right).<o:p></o:p></p></div><div><p class=MsoNormal><o:p> </o:p></p></div><div><p class=MsoNormal>I had a cell failure early on, and my system was 30, not 32V. Worked fine for years. <o:p></o:p></p></div><div><p class=MsoNormal><o:p> </o:p></p></div><div><p class=MsoNormal>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.<o:p></o:p></p></div><div><p class=MsoNormal><o:p> </o:p></p></div><div><p class=MsoNormal>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!<o:p></o:p></p></div><div><p class=MsoNormal><o:p> </o:p></p></div><div><p class=MsoNormal>Searching … 24V MIG is in remote storage with hen's teeth and unobtainium. <o:p></o:p></p></div><div><p class=MsoNormal>but discussion at<o:p></o:p></p></div><div><p class=MsoNormal><a href="http://forum.ih8mud.com/tools-fabrication/416445-snap-24v-portable-mig.html">http://forum.ih8mud.com/tools-fabrication/416445-snap-24v-portable-mig.html</a><o:p></o:p></p></div><div><p class=MsoNormal>confirmed that you can do stick with 24V.<o:p></o:p></p></div><div><p class=MsoNormal>AND somebody suggested this:<o:p></o:p></p></div><div><p class=MsoNormal><a href="http://store.cyberweld.com/twsgspgun10.html">http://store.cyberweld.com/twsgspgun10.html</a><o:p></o:p></p></div><div><p class=MsoNormal><o:p> </o:p></p></div><div><p class=MsoNormal>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.<o:p></o:p></p></div><div><p class=MsoNormal><o:p> </o:p></p></div><div><p class=MsoNormal>I hope this helps!<o:p></o:p></p></div><div><p class=MsoNormal>Windy<o:p></o:p></p></div><div><p class=MsoNormal><o:p> </o:p></p></div><div><div><p class=MsoNormal><span class=apple-style-span><span style='font-size:13.5pt;font-family:"'Marker
","serif"'>Windy Dankoff</span></span><span style='font-size:13.5pt;font-family:"Marker Felt","serif"'> Solar Bozo Emeritus</span><span style='font-size:13.5pt;font-family:"Helvetica","sans-serif"'><o:p></o:p></span></p></div><div><p class=MsoNormal><span style='font-size:9.0pt;font-family:"Helvetica","sans-serif"'><o:p> </o:p></span></p></div><div><p class=MsoNormal><span style='font-size:9.0pt;font-family:"Helvetica","sans-serif"'> Specialist in solar-electric applications & solar water pumping</span><span style='font-size:13.5pt;font-family:"Helvetica","sans-serif"'><o:p></o:p></span></p></div><div><p class=MsoNormal><span style='font-size:9.0pt;font-family:"Helvetica","sans-serif"'> Education <> Industry support <> Since 1975</span><span style='font-size:13.5pt;font-family:"Helvetica","sans-serif"'><o:p></o:p></span></p></div><div><p class=MsoNormal><span style='font-size:9.0pt;font-family:"Helvetica","sans-serif"'> ---------------------------------</span><span style='font-size:13.5pt;font-family:"Helvetica","sans-serif"'><o:p></o:p></span></p></div><div><p class=MsoNormal><span style='font-size:9.0pt;font-family:"Helvetica","sans-serif"'> Founder, retired, Dankoff Solar Products, Inc.</span><span style='font-size:13.5pt;font-family:"Helvetica","sans-serif"'><o:p></o:p></span></p></div><div><p class=MsoNormal><span style='font-size:9.0pt;font-family:"Helvetica","sans-serif"'> spin-offs: Dankoff Solar Pumps • Positive Energy • Conergy USA</span><span style='font-size:13.5pt;font-family:"Helvetica","sans-serif"'><o:p></o:p></span></p></div><div><p class=MsoNormal><span style='font-size:9.0pt;font-family:"Helvetica","sans-serif"'> Co-author, work in progress:</span><span style='font-size:13.5pt;font-family:"Helvetica","sans-serif"'> </span><u><span style='font-size:9.0pt;font-family:"Helvetica","sans-serif"'>The Handbook of Solar Water Pumping</span></u><span style='font-size:13.5pt;font-family:"Helvetica","sans-serif"'><o:p></o:p></span></p></div><div><p class=MsoNormal><span style='font-size:13.5pt;font-family:"Helvetica","sans-serif"'><o:p> </o:p></span></p></div><div><div><p class=MsoNormal><span style='font-size:10.0pt;font-family:"Helvetica","sans-serif"'>12-minute TV interview:<o:p></o:p></span></p></div><p class=MsoNormal><span style='font-size:10.0pt;font-family:"Helvetica","sans-serif"'><a href="http://www.youtube.com/watch?v=yt3hKgriSbo&list=TLrXFKMLwzCwuUD5h52WCzKdWRR-Juk3XA">http://www.youtube.com/watch?v=yt3hKgriSbo&list=TLrXFKMLwzCwuUD5h52WCzKdWRR-Juk3XA</a></span><span style='font-size:13.5pt;font-family:"Helvetica","sans-serif"'><o:p></o:p></span></p></div><div><p class=MsoNormal><span style='font-size:9.0pt;font-family:"Helvetica","sans-serif"'> ---------------------------------</span><span style='font-size:13.5pt;font-family:"Helvetica","sans-serif"'><o:p></o:p></span></p></div><div><p class=MsoNormal><span style='font-size:9.0pt;font-family:"Helvetica","sans-serif"'> <a href="mailto:windydankoff@mac.com">windydankoff@mac.com</a></span><span style='font-size:13.5pt;font-family:"Helvetica","sans-serif"'><o:p></o:p></span></p></div><div><p class=MsoNormal><span style='font-size:9.0pt;font-family:"Helvetica","sans-serif"'> Santa Fe, NM </span><span style='font-size:13.5pt;font-family:"Helvetica","sans-serif"'><o:p></o:p></span></p></div><div><p class=MsoNormal><span style='font-size:9.0pt;font-family:"Helvetica","sans-serif"'> home (505) 466-4280</span><span style='font-size:13.5pt;font-family:"Helvetica","sans-serif"'><o:p></o:p></span></p></div><div><p class=MsoNormal><span style='font-size:9.0pt;font-family:"Helvetica","sans-serif"'> cell (505) 490-0313</span><span style='font-size:13.5pt;font-family:"Helvetica","sans-serif"'><o:p></o:p></span></p></div><div><p class=MsoNormal><span style='font-size:13.5pt;font-family:"Helvetica","sans-serif"'><o:p> </o:p></span></p></div><div><p class=MsoNormal><span style='font-size:13.5pt;font-family:"Helvetica","sans-serif"'><o:p> </o:p></span></p></div></div><p class=MsoNormal><o:p> </o:p></p></div><p class=MsoNormal><br><br><br><o:p></o:p></p><pre>_______________________________________________<o:p></o:p></pre><pre>List sponsored by Home Power magazine<o:p></o:p></pre><pre><o:p> </o:p></pre><pre>List Address: <a href="mailto:RE-wrenches@lists.re-wrenches.org">RE-wrenches@lists.re-wrenches.org</a><o:p></o:p></pre><pre><o:p> </o:p></pre><pre>Change email address & settings:<o:p></o:p></pre><pre><a href="http://lists.re-wrenches.org/options.cgi/re-wrenches-re-wrenches.org">http://lists.re-wrenches.org/options.cgi/re-wrenches-re-wrenches.org</a><o:p></o:p></pre><pre><o:p> </o:p></pre><pre>List-Archive: <a href="http://lists.re-wrenches.org/pipermail/re-wrenches-re-wrenches.org">http://lists.re-wrenches.org/pipermail/re-wrenches-re-wrenches.org</a><o:p></o:p></pre><pre><o:p> </o:p></pre><pre>List rules & 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