How To Wire a 220 Outlet For A Welder: Welding In Wiring

A vital query that every beginner involved in welding professional asks is how to wire a 220 outlet for a welder? Being in this profession, perfect handling of welding machines or welding guns must come easily to all.

But these machines require quite a high amount of current to run, and thus its respective wiring must fulfill the requirements. Welding machines that require low voltage can operate with regular plugs at home. But those with higher voltage need plugs that can capacitate higher voltage.

Thus, substantial wiring is crucial for welders that require a 220V outlet. These wirings are a collection of wires joined together to use in a welder to complete the circuit. This article will focus on detailing a 22V outlet and the procedure to wire it for a welding machine.

We have also provided many necessary tools that must be available at our disposal to save extra time. Further, there is also a list of precautionary measures that one must undertake to make it a secured one. Without further delay, let us get started. 

A Detailed Explanation of a 220V Outlet

Although there are quite a few powerful plugs, 220V is the commonly used one. Their ability to operate high-power consuming appliances makes them preferable. If you do not know how to recognize a 220V output, search for the one which is comparatively thicker. 

Installing a 220V outlet is not an easy task and thus will require a lot of experience. Provided you have previous experience, you are good to go. Or else, it is better to depend on a professional in this field. 

In terms of its features, a 220 V outlet is triangular. There are three large holes in this pattern, each hole in every corner of the triangle. Two out of these three are for the black and red wires. The remaining hole is to accommodate the neutral wire connecting to the neutral port in the electric panel. 

Working Procedure of a 220V Outlet

Most electrical sub-stations deliver electricity at a range of 220V as it is faster and can cover longer areas in terms of distance. Usage of copper wire is lesser in transferring 220V current than in others. As soon as the current hit the transformer, the phase system spits the current into the three-wire mode.

One phase of the transferred 220V segregates into two 110V, which also shares a neutral wire. This neutral wire is known as the ground wire, which helps in preventing short circuits. 

As a result, it keeps moving towards the ground wire due to its neutral state. The excess electricity passes down through it, and the required one moves through the other two 110V holes and operates the appliances and machines. 

Types of 220V outlets

As already mentioned, a 220V outlet is usually for high-power appliances and machines. However, these outlets may either be of three-prong holes or four-prong holes. The missing prong is the primary difference between the two. Details of both of them are as follows:

Three-Prong 220V Outlet

Different appliances or machines have different needs in terms of energy consumption. 

  • Most traditional 220V outlets have three-prong holes, which contain a ground wire for transferring the extra current back to the ground. 
  • Two out of three prongs connect the red and black wire, passing the current to the machine. 
  • While connecting the 3-prong plug to the receptacle, the grounding wire connects and provides a passage for the current to flow back from the appliance to the breaker box. 
  • Besides, this path ensures utmost safety during an instance of a short circuit. 

Note: The main reason for the grounding wire in the 220V outlet is only to provide safety. It does not play any role in the operation of the machines. 

Four-Prong 220V Outlet

Heavy-duty appliances like welding machines require a much different outlet, structurally different from the three-prong ones. These are usually the 4-prong outlets that carry 220-volt current but have two different ports for ground and neutral paths. 

  • An extra prong is for ensuring better safety while using heavy machines, which consumes more power. 
  • The potentiality of shock is comparatively less in these outlets and thus a lot safer. 
  • Modern machines are equipped with four-prong wires to have a dedicated wire to the ground path, which does not interfere in any other function. 
  • If any appliance has a three-prong outlet, it will not fit into the four-prong outlet and requires a replacement in the cord. 

How to Wire a 220 Outlet for a Welder

Handling electricity and its related works is not as easy as it sounds. A professional degree or years of experience is mandatory in these cases for ensuring safety. The solution of how to wire a 220 outlet for a welder also will require some basic installation skills and some electrical knowledge.

Ensure that you are confident to pull-off this task and have a senior’s guidance to help during the process. Welders that require 220V to power up are more efficient in their performance as they receive more heat in a concentrated manner.

Thus, regular outlets at home will not be sufficient for welding tasks. Strong and perfect wiring is necessary for welders so that they receive continuous current during its operation. 

Below mentioned is a step-by-step process for wiring a 220V outlet for a welder. 

How To Wire a 220 Outlet For A Welder: Phase 1: Circuit Breaker

Since you will be handling an electrical unit, all-round safety is crucial. To prevent any damage to the outlet, turning off the circuit breaker is the first task. An electrical switch can detect an unusual flow of current either due to overloading or a short circuit.

These steps will help in turning it off before starting the wiring procedure:

Step 1: Locate the circuit board.

Step 2: Identify the switch for the circuit breaker.

Step 3: It will be in the ON position.

Step 4: To turn it off, flip it in the opposite direction.

How To Wire a 220 Outlet For A Welder: Phase 2: Access to Breakers

Once the circuit breaker is off, remove the metallic cover, which will then expose the breakers. Please search for a space for accommodating the two-pole breaker in it.

Keeping all the requirements at an arms distance will make the procedure faster. Attach the two gang box on the wall space and screw it up with a screwdriver. 

How To Wire a 220 Outlet For A Welder: Phase 3: Placing Two-pole Breakers

There will be two spaces available together to place the breaker box. Once you are sure about the space, measure the distance from the circuit breaker to the outlet. 

Also, ensure to measure the shortest distance so that it is easier to connect the wires through it. A marking on the desired place will solve the issue and will not require frequent measurements. 

How To Wire a 220 Outlet For A Welder: Phase 4: Wiring

For this phase, you will require a certain length of wire and a cable ripper

Step 1:

From a long wire, cut out a length of approximately six inches. Use a cable ripper to cut out the outer covering and expose the wires with a plastic sheath. Cut out this plastic sheath of around 12 inches and keep it separately to use inside the breaker box

Step 2:

One end of the wire is for the breaker box and the other for the 2-gang box. Locate the two screws on the breaker. Connect the hot wire on both of these screws, i.e., the black and red wires inside the breaker box

Step 3:

Ensure that the screws are secure. Screw up the ground wire on the ground bar and make sure it is not the neutral bar. The fourth wire does not have any requirement in this wiring procedure. The simple coiling of this one is sufficient. A round of double-checking is necessary

Step 4:

From the remaining sheath, cut out just an inch of the sheath from the tip. To prevent corrosion of this tip, you can use a non-corroding coating. Once all the wires are in place, but the outer covering and screw it up securely

Step 5:

Use a screwdriver to secure the casing and prevent it from opening up. Repeat the same procedure in the gang box and ensure that the connection is secure. Cover up the box, and the welder is ready for the plugin. If you are confident enough about the secure connection, turn on the power supply

Required Tools

  • Wire: Although you will need a six-inch wire, you may opt for some extra length as per the space available in the circuit box. Prefer a wire that is flexible and has a tough and heat-resisting covering. Quality material will ensure durability and prevent short-circuit.
  • Flush mount two gang box: Select those flush mount outlets which accompany switches, jacks, and keypads. These are connectible on the walls and does not require separate coverage. 
  • Flush mount outlet: For wiring a 220V outlet for a welder, you will need a 50amp flush mount welder outlet. 
  • Two pole breakers: These pole-breakers have dual hot wires which connect each other with one neutral wire. They are safer because, in case of overloading, both of these hot wires trip and disrupt the circuit. 
  • Non-corrosive material: A material like copper tape will help in protecting the tips of the exposed wire. They are a simple solution and are quite strong, and has high conducting power, which protects the wires from corrosion. 
  • Ripper: For exposing the inner copper wires inside the cable, use a quality cable ripper. it makes exposing the strips much easier and is also safe. Although many prefer using a blade, it may cut the wires in the process. Most of them also have certain holes so that it is convenient to slit without ripping the insulated wires. 
  • Screwdriver: For securing the screws in the cover and prevent falling off. 

Cautions

During wiring a 220V outlet for a welder, it is essential to maintain utmost safety. Since handling electricity and electrical equipment are quite critical, you must be very careful while wiring.

Further, the entire process must be substantial to prevent any hazardous incident during the welder’s use. Let us discuss some of the vital precautionary measures that will help in maintaining utmost safety. 

  • To be on the safer side, ensure to use welding gloves and not bare hands
  • Try remaining away from water storage containers and keep yourself dry during the wiring procedure. Ensure that the surface is dry in and around the operating space
  • Please ensure that the main power is off so that there are no shock incidences during the process
  • Once you turn off the circuit breaker, locking the handle will make it more secure
  • It is advisable not o touch any other metallic objects before turning off the breaker box switch
  • Using quality materials in the wiring will prevent electric shocks. Besides, all other equipment will be resistant to damage after wiring. A short circuit takes place when the wires are of low-quality and cannot withstand overloading
  • Use the wires as per the required specifications of the welding machine to withstand the excess power
  • Both wires and outlets must match the welder
  • Use a standard material for covering the tip of the exposed wire to prevent it from corrosion

Conclusion

Following all the steps appropriately will make the wiring procedure quite smooth and hassle-free. To fasten the process, keep all the necessary items within reach so that there is no time loss. Professional help is mandatory if you are a beginner in the electric connection field.

Since the wiring for a welder requires a substantial connection, improper installation may damage the welder. We hope this article covered all the necessary points that most of you were looking for. Ensure to remain safe and follow all the precautionary measures for safe wiring. 

Leave a Comment