Wiring the 3 phase EX to single phase 220VAC

[everlastsupport]

We have had a few calls on 1/3 phase units. There are stickers on the wires that seem to be a little confusing. So here is what you do.

Green or Green/yellow is ground. Black to a one hot leg, white to the other hot leg and cap off the (unused) red wire.

[performance]

Yes,

To simplfy the wiring process, we have stickers that are supposed to be on the end of the wires. They are small and sometimes fall off, othertimes, people just don't see them. The little tags should read 1x220 or something to that effect. These are the "hot" wires. Practically speaking, it doesn't matter to the machine which wires are hooked to which terminal. Technically speaking, your local wiring codes may require a particular color to be wired to a particular side of the plug.

But with most store bought welder plugs, the wiring information is in there to match the correct wire color to the correct terminal/blade. We have tried to standardize the wire colors to the U.S. standards, so that it is easy and simply to correctly wire the units.

Just as with other manufacturers, we don't include plugs at this time with all our units. With many diverse possible connections, and connectors, it is impossible to predict what type connection to 220 or 220 3 phase our customers may have. Some have accepted twist locks. Others have the standard 3 prong welder plugs. Others have the older 3 prong "crows foot" plugs that are common with older appliances. Some wire the unit directly into the panel.

So, at this time we have elected NOT to provide the plugs on our units. This will hopefully limit the confusion. It will be easier for the customer to buy a male plug for the welder that matches their connection than it will be to try to adapt a plug for their setup or even try to rewire their female wall receptacles.

[whitehendrix]

if i might add something, i think the most confusing thing is the presense of a green wire in general as a phase conductor. by code, i want to say thats "illegal" in itself, and the green/yellow is almost a perfect match to it's current-carrying brother.

i was taken back a bit at first when i first saw that, and my specialty is control wiring!! but when i saw the green/yellow i knew i didn't have to trace wire terminations at that point. i knew that was the ground.

maybe limiting the green to a ground only will help everyone with any confusion... Black and Red for single phase machines and Black, Red, Blue for polyphase.

green remains ground no matter what the configuration or phase voltage is.. (if it's a 480v machine for instance)



i didn't mind supplying my own plug but i couldn't tell using the nameplate rating what the primary current draw was either.. i opted for a 50A plug, but only needed a 30, which was specified in the manual, but not on the machine or the website.

just my .002

[performance]

The wiring on the older units was a little confusing, but the wiring was done to international standards.


The new units are standard U.S. wiring code colors. Black and white for single phase 220...Red is for 3 leg operation of 3 phase. Green is ground.

[whitehendrix]

ah.. gotcha.
thanks man!
i see you have these things covered like a fat chick on a toilet seat

[everlastsupport]

We're always watching and improving, that's for sure.

A new line for helmets are in the works as well as use of the unit improvements.

Not that the existing units are not good (I have 3 myself). But when people offer good advise and ideas we take them serious.

[mojojo]

Hi Performance, I know this is an old post but I just received my
Powermaster 256 AC/DC tig/plasma and I would like to know if the the green wire is ground, there are posts that say it is a hot leg.
and yours here says it is ground. Very confusing documentation.
I am ready to attach a 50 amp plug, the manual is know help at all.
This unit was manufactured and tested and inspected on
12/16/2009
Thank you
Joe Miller

[performance]

The wiring on the older units was a little confusing, but the wiring was done to international standards.


The new units are standard U.S. wiring code colors. Black and white for single phase 220...Red is for 3 leg operation of 3 phase. Green is ground.

Green is ground on all new units, including yours. I believe the newer models started in 2008 with the new style with green being ground, starting with the yellow units.

[mojojo]

Thank you, for the quick reply to a question that has been answered
a million times
OK I can't wait to crank this bad boy up.