Good afternoon! I am currently working on implementing arc-on time tracking for manual welders to justify investing in better jigs. I have a spare PLC that I planned to use to monitor when significant currents are flowing into the welding machines. I have tried out various AC current monitoring switches, including the Johnson Controls CSDSC-C50100L, Eaton ECSNOASP, AcuAmp ACS150-AE-S, and AcuAmp ACSN250-AE-S. Despite ensuring proper setup and testing around different power sources, I am still facing issues with getting them to function. I am exploring alternatives to avoid cutting and rewiring cables, as my goal is to install these switches at multiple manual welder stations within a large facility. I am hesitant to create separate mini panels for each device, as it would involve dealing with high voltage power cables. Additionally, I have considered DC switches, but the cables from the welder to the torch are significantly thick. Any insights or suggestions on where I may be going wrong in my setup process would be greatly appreciated. Thank you in advance!
Have you considered attaching the clamps to the power supply cable or cord that powers the welder? If so, you should observe zero net amps when combining the line and neutral currents. However, it is possible for the clamps to be effective when connected to the welding lead leading to the electrode.
In response to a query by joseph_e2, I have installed the device on the power supply cable leading to the welder. While I expected to see zero net amps (Line + neutral = 0), I was surprised to find conflicting information as one source listed monitoring welders as a recommended use for the device. The advantage of using a split-core design is the ability to fit it around an existing cable. I plan to take measurements and search for a DC switch capable of handling the thick cable leading to the welding torch.
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From your description, it seems like you've done a great job covering all bases when it comes to AC switches. If you're concerned about the thickness of cables, have you considered cable-free current sensors such as Rogowski coils? These might be an ideal solution for your situation—they're flexible, easy to install even on large conductors or busbars, and they don't require any cable cutting. For the PLC part, you just need a transducer to convert the coil output into a signal your PLC can read. Utilising this approach could potentially simplify your installation process. However, do consider the accuracy as certain types may not be as precise as direct couplers.
Hi there! Have you considered using clamp-on ammeter probes or current transducers? These can be easily used without the need to cut and rewire your system. They physically clip around the cable and use magnetic fields to determine the amount of current flowing through it. Because you're dealing with such thick cables, choose models that accommodate large wire sizes. One such option that comes to mind is the Fluke i2000 Flex. These can interface directly with your PLC analog input, making it a versatile choice. It's something I've used in similar situations, and might just fit the bill here. Remember though, this set-up would need to be validated to ensure it's accurately measuring the arc-on times. Good luck!
Hey! It sounds like you’re dealing with quite a challenge, but you're on the right track with wanting to monitor current for justifications on your jig investment. One thing to consider is whether you're using the proper current transformers (CTs) that can handle the thick cables without needing extensive wiring changes. Sometimes, clamp-on CTs can be a less invasive solution, allowing you to measure the current without cutting into existing cables. Also, make sure the calibration of your monitoring switches matches the expected range of the currents you're measuring; sometimes that can lead to misreadings. Have you looked into wireless options for easier installation too? Good luck!
It sounds like you’re tackling a challenging project! Have you considered using current transformers (CTs) instead of the switches you’ve been testing? CTs can provide a non-invasive way to measure AC current without needing to cut into existing cables, making them easier to implement at multiple stations. They also come in various sizes to handle thick cables, and you can often integrate them with your PLC for real-time monitoring. Just make sure to pair them with the appropriate interfacing components for your PLC input specs. This could simplify your setup and help you avoid some of the headaches you’re experiencing!
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Answer: - The common AC current monitoring switches mentioned in the thread are Johnson Controls CSDSC-C50100L, Eaton ECSNOASP, AcuAmp ACS150-AE-S, and AcuAmp ACSN250-AE-S.
Answer: - The purpose of implementing arc-on time tracking for manual welders is to justify investing in better jigs.
Answer: - Despite proper setup and testing, the current monitoring devices are not functioning as expected in the large facility.
Answer: - Concerns include avoiding cutting and rewiring cables and the hesitation to create separate mini panels due to dealing with high voltage power cables.
Answer: - DC switches have been considered as an alternative, but the thick cables from the welder to the torch pose a challenge.
Answer: - Insights or suggestions are requested on potential errors in the setup process for the current monitoring devices.
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