How to use the most standard rod welding machine in 2024

Rod welding machines are important tools in industry and construction. In order to use rod welding machines effectively and safely, this article will provide detailed instructions from how to use the welding machine and some notes when using electronic welding machines, safety principles, and introduce the common types of rod welding machines today.

1. Instructions on how to use the rod welding machine

Step 1: Install the welding wire, mass wire into the electronic rod welding machine

• Most electronic rod welding machines come with accessories such as welding wires, mass wires, welding clamps, mass clamps.
• Insert the mass wire into the negative terminal and the welding wire into the positive terminal of the welding machine. Make sure to fit the correct joint (tighten clockwise) and place the mass clamp away from the weld line for easy welding.

Step 2: Attach the welding rod to the welding clip

Step 3: Set up the welding line

• On each rod welding machine, there is a knob that adjusts the welding flow (welding current strength, in Amps). Choose the welding line that is suitable for the welding rod diameter: the welding rod with a large diameter adjusts the large welding line and vice versa.

Step 4: Supply power to the welding machine

• The welding machine uses a 220V or 380V power supply (the 3-phase power supply is only suitable for industrial welding machines).
• Make sure the On/Off switch is off before plugging the power cord into the power supply to avoid unnecessary problems such as self-operation.

Step 5: Perform welding

• Bring the welding rod to the position to be welded, turn on the switch to power the welding machine, and start the welding process.

2. Some tips for beautiful rod welding

Clean the solder before soldering

In order to ensure a beautiful and quality weld, it is very important to clean the weld before welding. Use a slag hammer or scrubbing table to remove welding slag, dirt, and other impurities. This not only makes the weld more beautiful but also increases the adhesion and strength of the weld.

Use the right welding rod for the welding line

Choosing the right welding rod and adjusting the welding flow is important:

• Welding rod diameter 2.5mm: welding line 50 – 90A
• Welding rod diameter 3.2mm: welding current 90 – 130A
• Welding rod diameter 4.0mm: welding line 140 – 190A
• Welding rod diameter 5.0mm: welding current 180 – 240A

Improper setting of the welding current intensity can cause many problems such as sparks, border burns, weld punctures (too high current) or stick sticking, low swallowing, poor welding quality (too low current).

Arc Adjustment for Rod Welding Machine

The arc length (distance from the welding rod to the welding object) should range from 1.6mm to 2.4mm. Longer arcs allow for the use of larger electrodes, diameters, and welding currents, but should not be larger than the electrode core diameter. An arc that is too long reduces the embankment performance and weld quality, and is too short, causing a short circuit in the process of metal displacement.

Welding Tilt Angle Adjustment

• On a flat surface: tilt the welding rod 5 – 15 degrees in the direction of movement.
• In the vertical position: the angle of the welding rod is from 0 – 15 degrees in the opposite direction to the direction of movement of the welding rod.

Perform the welding rod operation

There are 4 main types of movement:

• Horizontal Movement: Ensure the width of the weld.
• Vertical Motion: Weld the entire length of the weld.
• Continuous movement
• Intermittent Motion

These movements cannot be applied to all welds. With thin welding materials, horizontal movements should not be applied because it is easy to puncture the weld. It is recommended to apply vertical and intermittent movements.

Clean the weld after welding

After the welding is complete, use a hammer or wire brush to clean the welding slag. Use a die grinder to smooth the weld, increasing the aesthetics of the welding result.

3. Notes on when using an electronic rod welding machine

Fully equipped with protective gear

When using a welding machine, it is necessary to be fully equipped with protective equipment such as protective clothing, masks, welding masks, protective glasses and gloves. These are indispensable equipment to protect your health and safety during the welding process. Welding fumes can cause dangerous respiratory diseases, especially in small and poorly ventilated workspaces, so welding masks and specialized masks are essential. Besides, electric arcs can be harmful to the eyes, so eye protection glasses are also an indispensable item.

Inspect the welding machine before use

Before use, double-check the parts of the welding machine to make sure it is in stable condition. Check the extension cords and machine parts for breakage, damage, or malfunction. This inspection helps to ensure that the machine is operating efficiently and prevents the risk of reduced capacity, reduced service life, or serious incidents such as fire and explosion.

Double-check the welding area

The welding area also needs to be thoroughly inspected before starting work. Welding slag and sparks can cause fire and explosion if the welding area is not thoroughly inspected. Welding in a humid space can cause electrical shorts and electrical leakage which is very dangerous. Therefore, make sure the welding area is dry and free of flammable materials.

Proper storage of the welding machine

Proper storage of the welding machine is an important factor in maintaining the performance and longevity of the machine. Place the machine in a cool, dry place away from moisture and direct sunlight. Do not leave the machine near flammable and explosive materials. Clean and check the machine regularly with specialized tools to keep it in good working order.

4. Guidelines for safe use of welding machines

4.1. Electrical safety when using welding machines

To ensure electrical safety when using a welding machine, please comply with the following notes:

• Avoid direct contact with conductive components of the welding machine.
• Use insulating items to isolate from the object to be welded and the ground.
• Make sure each welder is powered from a separate circuit breaker and check the power supply before disassembling the welder.
• Avoid leaving the power cord on the ground or coming into contact with metal.
• Check the welding clamp handle to ensure good insulation and heat resistance.
• Regularly inspect and replace damaged or scratched cables.
• Make sure the soldering wires and cool wires are not peeled off, the joints are sealed with insulating tape.
• Always wear protective gear such as clothing, welding glasses, gloves, aprons, and insulated shoes when using the welding machine.
• Turn off all power when not in use.
• Be careful when welding in wet environments or difficult positions.
• Learn the shock resistance of the welding machine and do not use homemade or damaged welding pliers.

4.2. Safety when welding

• Do not weld metal in closed vaults, cavities, and tanks that are under pressure or contain flammable and explosive substances. If you need to weld in these spaces, you must master the technique, have expertise, and have a supervisor.
• Carry out ventilation, dust extraction and local ventilation at the welding site.
• Use welding glasses and a protective hat to avoid electric arcs that harm the eyes and skin.
• If the eye is slightly damaged, apply ice to reduce swelling and apply 1-2 drops of 1% cyclopentolate. Do not touch the weld or the object to be welded when the weld is finished.
• Use protective gear to prevent metal rays from flying into your eyes.

4.3. Safe against welding fumes

During the welding process, the two main types of fumes, MMA and FCAW welding, can produce a lot of toxic fumes:

• Wear a mask to avoid inhaling toxic fumes.
• Use a gas mask and fan if working in an unventilated space.
• Keep the head away from the soldering smoke area so as not to inhale the fumes.

4.4. Fire safety when using welding machines

• Place the welding machine in a place where there are no passers-by and use a shield of non-combustible material.
• Comply with regulations on fire and explosion safety when welding in places where there is a risk of fire and explosion.
• When welding at height, make the floor with a fireproof material or wear a seat belt and have a tool bag, a piece of excess welding rod.
• Assess the safety of the environment before welding and clean up flammable equipment from the welding area.

5. Top 3 common types of rod welding machines today

5.1. Jasic ZX7-250E Electronic Rod Welding Machine

Jasic ZX7-250E electronic rod welding machine owns modern Inverter technology and powerful power, operating stably in a high humidity environment. The machine is capable of continuous welding of rods from 1.6-3.2mm, suitable for many fields such as construction, civil, and automobile workshops. The product has an 18-month genuine warranty, ensuring quality and durability.

5.2. Jasic ZX7-200E Electronic Rod Welding Machine

Jasic ZX7-200E has a compact design that is easy to move and store. The machine adopts advanced technology of anti-overload and anti-shock, and has high anti-stick ability. This is a suitable choice for beginners thanks to its reasonable price.

5.3. Hong Ky HK 200N electronic rod welding machine

Hong Ky HK 200N has an output power of 7 KVA and a rod soldering capacity of up to 3.2mm. The machine is powder coated, which has high durability and good resistance in harsh environments. The machine also saves 50% – 60% of electrical energy compared to other rod welding machines on the market.

6. Conclusion

The proper use of a rod welding machine not only ensures the quality of the weld, but also ensures the safety of the user. Hopefully, this article will provide you with all useful information on how to use a welding machine effectively and safely. Following the safety instructions and guidelines when using a welding machine will help protect workers’ health and extend the life of the equipment. In addition, this year, if you want to learn more about the latest production methods, you can immediately participate in  the Vietnam Manufacturing Expo organized by RX Tradex Vietnam, with the participation of hundreds of leading brands.