Republic of the Philippines

Department of Education
Region VII, Central Visayas
Division of Cebu Province
DISTRICT OF BALAMBAN II

School : BUANOY NATIONAL HIGH SCHOOL Inclusive Week: WEEK 8 & 9

Grade/Section : GRADE 9 Subject Area: SMAW 9

I. MELC : Set-up welding machine (TLE_IAAW9SW-Ih-1)

Set-up welding accessories (TLE_IAAW9SW-Ii-2)
II. Objectives : In this activity, you will be able to:
Knowledge : identify different parts of a welding machine and welding accessories
Skills : determine welding machine according to current use and specifications
Values/Attitude : promote critical thinking among the learners in performing the activities
III. Subject Matter : Identify welding machine parts and types of welding power source
IV. References
 Curriculum guide
 http://shop.goldpeaktools.com.ph/pages/yamato-welding
 http://www.citihardware.com/product/category/111
 http://www.cruxweld.com/welding-cutting-equipment/welding-rectifier-400-2/
 https://m.made-in-china.com/product/Made-in-China-Two-in-One-Imitative-Welding-Generator-DC-Welding-
Generator-Welding-Machine-Generator-777743315.html
 Weldingheadquarters.com

V. Procedure
A. Readings
WELDING POWER SOURCE
The function of a power source is to provide the voltage necessary to maintain an arc
between the electrode and the workpiece and a sufficient supply of electric to melt the surface of
the workpiece and the end of the electrode.
Power sources may supply direct current (DC) or alternating current (AC) to the electrode.
AC is the most common power supply due to the lower cost and simplicity of the welding machine,
however, DC has some advantages. The DC arc is noticeably more stable when using certain
types of electrodes DC is better for sheet metal.
ALTERNATING CURRENT WELDING CIRCUIT
An AC only SMAW power source is the most economical type of welding power source
available. Because of the alternating characteristic of the current, however, the resulting arc and
weld will tend to have more spatter, less penetration, and more arc outages than a weld made with
direct current. One situation when alternating current would work better than direct current is if the
operator is encountering magnetic arc blow.
DIRECT CURRENT WELDING CIRCUIT
DIRECT CURRENT is the most common current choice for stick welding. The current flows
in one direction only and has many advantages over alternating current for the stick process.
These
advantages include: fewer arc outages, less spatter, easier arc starting, less sticking, and better
control in out-of-position welds.
The polarity of the direct current welding arc or the direction of electrical current flow is very
important. When the electrode cable is connected to the power sources positive output connection
and the work cable is connected to the negative output connection this is a DCEP (Direct Current
Electrode Positive) or Direct Current Reverse Polarity connection. When the electrode cable is
connected to the negative and the work cable is connected to the positive this is a DCEN ( Direct
Current Electrode Negative) or Direct Current Straight Polarity connection.
For SMAW, the DCEP connection is used most often. It provides for the best penetration
and bead profile. For this reason most electrodes are made to weld with DCEP.
Using a DCEN connection for SMAW will result in a narrow bead with little penetration. This
connection works well when welding on sheet metal or for hard surfacing electrodes.
BASIC PARTS OF WELDING POWER SOURCE

The basic parts of a power source are shown in Fig. 1.1 the function of these parts.

Lever Switch

Welding Cable Outlets / Current Range Indicator

Secondary Winding Terminals

Current Adjusting Wheel

• Current adjusting wheel is rotated either clockwise (increasing) or counter clockwise

(decreasing) until the marker in the indicator is set to the desired current.
• Current range indicator provides the current output reading of the welding machine.
• Secondary windings terminals provides electrode holder cable and return cable
connections to the welding machine.
• Lever Switch provides/switches the machine ON/OFF whenever the machine needed for
operation.
TYPES OF POWER SUPPLY
 AC TRANSFORMER

Alternating current welding power sources are step down

transformers, which provide safe welding voltage. The welding current
supplied by the secondary circuit of the transformer is controlled by a
variable resistor in this circuit or by altering either the number of turns or
the magnetic leakage between the primary and secondary windings. Transformer welding
machines are less complex and expensive than other types.
 DC GENERATORS

The direct current generators have the advantages of a more

flexible control of arc characteristics and stable current. A close
-coupled electric motor or an internal combustion engine rotates the
armature in the generator. Varying the current flowing in the
generator field windings controls welding current.

 TRANSFORMER RECTIFIER

Transformer rectifier is designed to provide either DC or AC

outputs. With no moving parts like generators, they share with the
transformer the advantages of quiet operation, convenience and lower
cost.

 DC INVERTER TYPE

DC inverter type are designed to provide DC output. It is known to be

a portable welding machine, it is handy, quiet in operation, convenient
and lower cost.
WELDING ACCESSORIES
Welding Accessory is an external device that can be added to main equipment generating
multiple functions in order to make it more useful, versatile, or attractive'. In the context of welding,
the scope is wide and tends to include both consumables and non-consumables required to
perform a particular welding task.

Welding machine consist of a power source

with the accessories attached to it. Without these accessories, the welding machine will not
perform its functions.
Before attempting to install to a welding machine, you should be familiar with its accessories
before using the machine

 WELDING CABLES

The welding cables conduct from the power source to

the work. The electrode cable is connected to the electrode
holder. The return cable is connected to the return clamp. It is
designed for use in electric arc-welding machines to power an
electrode, a specially designed metal rod that conducts a
charge. The charge carried by the electrode is needed to
produce an electric arc, the heat source, between the electrode
and the metals being welded.
  GROUND CABLE / WORK CABLE

It connects the Grounding/Earthing Cable from the welding

machine to the base metal. The purpose of connecting the
equipment enclosure to ground is to ensure that the metal
enclosure of the welding machine and ground is at the same
potential. When they are at the same potential, a person will not
experience an electrical shock when touching the two points. All the
welding current passes through the earth clamp. Without a good earth connection, the
performance of the welder and the welding machine will be compromised; this can only mean one
thing: an inferior quality weld.

 ELECTRODE HOLDER

It connects to the welding cable then connects the welding

current to the electrode. The insulated handle is to guide the
electrode over the weld joint and feed the electrode over the weld
joint and feed the electrode into the weld puddle as it is consumed.
Electrode holders should be relatively light, fully insulated and sturdy
enough to withstand continual handling. Its function is to hold the
electrode at desired angle.
Electrode holder
 should be the amperage rating and in good condition for safe
 designed to be use at its maximum amperage rating or less
 Too large holder for amperage ranged used makes it hard for the manipulation and the
operator fatigue increases.
Welding Set-up Safety
 The arc welding should be properly place at the worksite and should be free from falling
sparks.
 The machine should be stacked to save space, but there must be room enough in the
machine for the air to circulate thus preventing hazards.
 Overheating. The air should be free from oil, dust, and metal fillings.
 The power should be turned off periodically and the machine should be clean after using.
 The machine should be away from the cleaning tank and any other source of corrosive
fumes that can be blown through it.
 The workstation should be free from combustible materials.
 Check the surrounding before starting to weld. There should be a safety watch. A safety
watch is a person who knows safety measures and who can warn another person in
danger.
B. Exercises
Exercise 1
Directions: Write T if the statement is true and F if the statement is false on the space provided.
___1. In welding, DCEP is same as DCSP
___2. AC is the most common current used in welding.
___3. You can use any type of electrode on whatever welding current you want.
___4. Transformer rectifier is designed to provide either DC or AC outputs.
___5. The polarity of the direct current welding arc or the direction of electrical current flow is very
important.
___6. To be safe while working, the workstation should be free from combustible materials.
___7. The ground cable connects the electrode holder to the welding machine.
___8. Too large electrode holder for amperage ranged used makes it hard for the manipulation
and the operator fatigue increases.
___9. The welding cables conduct from the power source to the work.
___10. The machine should be stacked to save space, but there must be room enough in the
machine for the air to circulate thus preventing hazards.

Exercise 2
Directions: Answer the questions below. Give the BEST answer.
1. In Direct Current Reverse Polarity, The electrode cable is connected to the __________?
2. a welding current that will result in a narrow bead with little penetration
3. a portable welding machine that is handy, quiet in operation, convenient and lower cost
4. welding machines that are less complex and expensive than other types
5. its function is to provide the voltage necessary to maintain an arc between the electrode and the
workpiece and a sufficient supply of electric to melt the surface of the workpiece and the end of
the electrode
C. Assessment/Application
I. Directions: Read the following carefully and choose the BEST answer.
1. What is the most economical type of welding power source available?
A) AC B) DC C) DCEN D) DCEP
2. it provides the current output reading of the welding machine
A) Current adjusting wheel B) Current range indicator
C) Lever Switch D) Power supply
3. A situation when alternating current would work better than direct current is?
A) Adjusting current B) Encountering magnetic arc blows
C) Fewer arc outages D) Less Spatter
4. a welding machine that has an internal combustion engine.
A) DC Generators B) DC Inverters C) Rectifiers D) Transformers
5. What polarity is used if the electrode cable is in the positive outlet?
A) AC B) DC C) DCEP D) DCSP
6. it provides/switches the machine ON/OFF whenever the machine needed for operation
A) Current adjusting wheel B) Current range indicator
C) Lever Switch D) Secondary winding terminals
7. it is a machine designed to provide either DC or AC outputs
A) DC Generators B) DC Inverters C) DC Rectifiers D) AC Transformers
8. Which of the following is NOT an advantage of a DC welding circuit?
A) easier arc starting B) fewer arc outages
C) less spatter D) more arc striking
9. In order to increase the current, the current adjusting wheel should be turned _______.
A) clockwise B) counter clockwise C) downward D) upward
10. What polarity is used if the electrode cable is in the negative outlet?
A) AC B) DC C) DCEP D) DCSP
11. welding machines that are less complex and expensive than other types
A) DC Generators B) DC Inverters C) DC Rectifiers D) AC Transformers
12. it is a machine designed to provide either DC or AC outputs
A) DC Generators B) DC Inverters C) DC Rectifiers D) AC Transformers
13. What is the polarity if the work cable is connected to the positive outlet?
 A) AC B) DC C) DCEP D) DCSP
14. _____ provides electrode holder cable and return cable connections to the welding machine
A) Current adjusting wheel B) Current range indicator
C) Lever Switch D) Secondary winding terminals
15. What polarity provides the best penetration and bead profile?
A) AC B) DC C) DCEP D) DCSP

16. It connects to the welding cable then connects the welding current to the electrode.
A) clamp B) electrode C) electrode cable D) electrode holder
17. ________ is an external device that can be added to main equipment generating multiple
functions in order to make it more useful, versatile, or attractive
A) electrode B) electrode holder C) machine parts D) welding accessories
18. It connects the Grounding/Earthing Cable from the welding machine to the base metal.
A) electrode B) electrode cable C) electrode holder D) ground cable
19. Its function is to hold the electrode at desired angle.
A) electrode B) electrode cable C) electrode holder D) ground cable
20. _____ should be relatively light, fully insulated and sturdy enough to withstand continual
handling.
A) electrode B) electrode cable C) electrode holder D) ground cable
II. Directions: Draw a welding machine with its accessories and label each parts. Use the space
below.

Prepared by:
 FELIX BERNAR R. MILAN Verified by:
Teacher I
SUSAN C. TRIBUNALO
Checked by: School Principal I
ROMMEL C. MELGAR
Subject Coordinator