Power plugs on single-phase Welders: Your questions answered

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We frequently receive inquiries from users of single-phase welding machines and plasma cutters. Common questions include: "What size plug should I use?" and "Can I connect my welder to a 10A plug?" and so on.

This article aims to address some of these frequently asked questions in straightforward, easy-to-understand language.

Please keep in mind that this is a complex topic to fully explain, and for a more comprehensive and technically detailed explanation, we would refer readers to the relevant Australian standards mentioned below.

 

Plug Size vs. Welding Machine Capacity

The Australian standard "AS60974.1 Arc welding equipment Welding power sources" specifies that the plug (and its corresponding power input cable) should match the "effective input current" rating of the machine.

The "effective input current" is usually indicated on the machine's data plate, denoted by the symbol I_1eff.
If a machine has an I_1eff rating of 10A or less, it can be equipped with a 10A plug.
If a machine has an I_1eff rating exceeding 10A up to 15A, it should be equipped with a 15A plug.
And so on.

The higher the output capacity of the machine (amps), the higher the I_1eff effective input current rating will be. Other factors influencing the I_1eff rating from one model or brand to another include efficiency, power factor, functions/processes, duty cycle, etc.

 

Understanding 'Effective Input Current Rating' (I_1eff)

In simple terms, I_1eff is somewhat like an average or median current draw. (The mathematical formula to calculate I_1eff is complex and depends on the duty cycle, efficiency, power factor, maximum output, and other parameters).

I_1eff should not be confused with the maximum/peak current draw (I_1max) of the machine, which will always be higher. For instance, a machine might have an I_1eff rating of 15A but an I_1max rating of 32A.

Additionally, note that the I_1eff rating takes into account the full or maximum output range of the machine. If a machine is being used at lower-than-maximum output and/or duty cycle, the 'actual' current draw of the machine at that moment will be lower than the I_1eff rating shown on the machine's data plate.

 

What Happens If I Use a Smaller Plug on My Welder?

Users often inquire about connecting a different (smaller) size plug to their welding machine to make it compatible with a more readily available or convenient power supply. For example, fitting a 10A plug to a machine originally supplied with a 15A plug, or even fitting a 15A plug to larger machines up to 250 amps or more.

Here are a few important points regarding this:

 

If a 15A rated machine, for example, is only used on relatively low output and/or duty cycle, the 'actual' effective current draw at that moment may be 10A or less. In such cases, some users might argue that a 10A plug could be used in this application.

Consider a Weldclass 205MST 200A welder with an I_1eff rating of 15A based on full output, but suppose we're only using it at 140A output at 15% duty cycle. In this scenario, the 'actual' current draw will be less than 10A.

Some larger machines on the market (e.g., 250A and above) come with two different output ratings/levels on the data plate to indicate the maximum output the machine should be used at in order to be compatible with different plug/circuit sizes. For example, a 250A machine with an I_1eff rating of around 20-30A at full output, but with additional ratings/data showing the maximum output to achieve an I_1eff of 15A for use with a 15A plug.

Certain Weldclass machines also offer the convenience of special programs that adjust the machine output to accommodate different power outlets. For instance, the 210MST MIG and 202T TIG have 10A/15A programs, while the 290MST MIG has 15A/32A programs.

As explained earlier, if the machine is not being used at high output and/or high duty cycle, this reduces the current draw and avoids overloading the power supply beyond its rated capacity, ensuring normal operation.

However, if the machine is used at high (or nearly maximum) current/amps and/or high duty cycle (welding frequently and/or for longer durations at a time), this increases the current draw.

When the machine's 'actual' current draw exceeds the rating of the power supply circuit/outlet, the circuit breaker is likely to trip.

Be aware that if a power circuit is overloaded (especially excessively or repeatedly), there is a risk of overheating the power supply circuit components and causing a fire hazard. This is why it’s crucial to adhere to the AS60974.1 I_1eff rating requirements outlined in this article.

In the case of Weldclass machines, using a 15A-rated machine on a 10A power supply is highly unlikely to damage the machine, as it will be operating at less than full capacity. While some brands/manufacturers claim this will void the warranty, this is not the case with Weldclass machines unless there has been negligence or misuse.

If using generator power, please refer to these guidelines.

 

No. The only difference between a 10A and 15A plug is the size of the earth pin. The earth pin is a safety feature and does not typically carry any current/power. The purpose of a larger pin on a 15A plug is simply to prevent it from being connected to a 10A power outlet.

 

 

While all care has been taken to ensure the accuracy of the information provided, Weldclass accepts no responsibility for any errors or omissions in this article. The information given is of a general nature only and does not take into account the specific circumstances of any individual application or situation. It should not be used as a substitute for professional advice (such as from a qualified electrician or electrical engineer). All applicable safety standards (including Australian standards), industry guidelines, and regulations should be consulted and followed. This article is intended to help readers without technical expertise or training (such as electrical engineering qualifications) gain a basic understanding of the topics discussed. As such, some terminology may be imprecise, and the information provided will not be a complete or exhaustive resource. Weldclass does not condone or recommend using any machine in a manner that contradicts Australian standards requirements or manufacturer’s instructions. E.&O.E.

 

We hope this clarifies some of the common concerns regarding plug sizes and welding machines. Always prioritize safety and consult professionals when unsure!

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