Upgrading Senko 787E Plus Spot Welder for Thicker Metals
| Upgrading the Senko 787E Plus Spot Welder for Improved Performance |
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As an enthusiast of DIY projects and metalworking, I recently found myself in need of a more reliable spot welder. My trusty Senko 787E Plus had served me well, but it was struggling to handle thicker materials like 0.2mm nickel strips. In this article, we'll explore the upgrade process that allowed me to take my welding capabilities to the next level.
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The original Senko 787E Plus spot welder is an excellent tool for thinner materials like 0.1mm and 0.15mm, but its limitations became apparent when attempting to work with thicker gauges. After researching possible upgrades and consulting with fellow enthusiasts, I decided to embark on a DIY upgrade project.
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To begin the upgrade process, I carefully disassembled the welder to identify areas that could be improved. The primary goal was to increase the available current to facilitate better welding performance with thicker materials. By upgrading key components and fine-tuning the internal settings, I aimed to significantly boost the welder's capabilities.
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One of the essential upgrades involved replacing certain parts to allow for higher current output. This included sourcing specialized components from reputable suppliers (a full list of upgraded parts and purchasing links can be found in the description section below). The upgraded parts enabled me to increase the welder's power, allowing it to handle thicker materials with ease.
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With the upgrades complete, I was eager to test the improved performance of my Senko 787E Plus spot welder. Welding a 0.2mm nickel strip proved to be a successful trial run, showcasing the upgraded tool's ability to produce strong, reliable welds.
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To verify the quality of the welds, I employed a simple yet effective test: attempting to remove the welded portion forcefully. If the weld holds and shows no signs of weakness or separation, it's a good indication that the upgrade was successful.
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As expected, the upgraded Senko 787E Plus passed this test with flying colors, leaving distinct "tear holes" in the surrounding material. This visual confirmation validated the efficacy of my DIY upgrade project and provided assurance that I can now tackle thicker materials with confidence.
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By investing time and effort into upgrading my trusty Senko 787E Plus spot welder, I've managed to unlock its full potential. The improved performance will undoubtedly expand the range of projects I can undertake, allowing me to explore new possibilities in metalworking and DIY endeavors.
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| Welder Upgrade |
The Welder Upgrade is a popular modification for welders that aims to improve their performance and efficiency. |
| Background |
The idea of upgrading a welder's equipment and skills has been around for decades. However, with the advancements in technology and the increasing demand for high-quality welding services, the need for a comprehensive upgrade solution became apparent. |
| Key Features |
The Welder Upgrade typically includes a combination of hardware and software upgrades, such as improved welding guns, enhanced power sources, and advanced computer controls. These upgrades enable welders to achieve higher accuracy, precision, and speed. |
| Benefits |
The Welder Upgrade offers numerous benefits, including increased productivity, improved weld quality, reduced downtime, and enhanced operator safety. Additionally, the upgrade can help welding businesses to stay competitive in the market and expand their customer base. |
Upgrading Senko 787E Plus Spot Welder for Thicker Metals |
| Introduction: |
The Senko 787E Plus Spot Welder is a popular and versatile welding machine that can handle various metal thicknesses. However, when working with thicker metals, it may not provide the desired results. In this article, we will discuss how to upgrade your Senko 787E Plus Spot Welder to effectively weld thicker metals. |
| Understanding the Limitations: |
The Senko 787E Plus Spot Welder has a maximum welding capacity of 1/4" (6mm) for steel and 3/8" (9.5mm) for aluminum. If you need to weld thicker metals, you may encounter issues with penetration, porosity, or lack of fusion. |
| Upgrades for Thicker Metals: |
To upgrade your Senko 787E Plus Spot Welder for thicker metals, consider the following options: |
| • Increasing the Welding Current: |
Adjust the welding current to a higher setting (up to 150A) to increase the heat input and penetration. |
| • Using a Higher Capacity Transformer: |
Replace the standard transformer with a higher capacity one (e.g., 10KVA or 15KVA) to provide more welding power. |
| • Adding an External Welding Capacitor: |
Install an external welding capacitor (e.g., 100uF or 200uF) to filter the welding current and improve arc stability. |
| • Upgrading the Electrodes: |
Use higher-duty electrodes (e.g., RW-1 or RW-2) designed for thicker metals, which provide better conductivity and durability. |
| Additional Tips and Precautions: |
When working with thicker metals, ensure proper joint preparation, maintain a consistent welding technique, and monitor the weld pool closely to avoid overheating or porosity. |
| Conclusion: |
Upgrading your Senko 787E Plus Spot Welder for thicker metals requires careful consideration of the welding process and equipment modifications. By implementing these upgrades and following best practices, you can effectively weld thicker metals and achieve high-quality results. |
| Q1: What is the purpose of upgrading a Senko 787E Plus Spot Welder? |
The purpose of upgrading a Senko 787E Plus Spot Welder is to enable it to handle thicker metals that are beyond its original capacity. |
| Q2: What are the limitations of the standard Senko 787E Plus Spot Welder? |
The standard Senko 787E Plus Spot Welder is designed to handle metals up to a certain thickness, typically 1/4 inch (6 mm). Beyond this thickness, the weld quality may suffer. |
| Q3: What upgrades are available for the Senko 787E Plus Spot Welder? |
Available upgrades include increasing the transformer tap, adding a secondary capacitor, and installing a more powerful electrode. |
| Q4: How do I increase the transformer tap on my Senko 787E Plus Spot Welder? |
To increase the transformer tap, you need to access the transformer and adjust the tap switch. This may require soldering or replacing wires. |
| Q5: What is the purpose of adding a secondary capacitor to the Senko 787E Plus Spot Welder? |
The secondary capacitor helps to filter out electrical noise and improve the weld quality, especially when working with thicker metals. |
| Q6: Can I upgrade my Senko 787E Plus Spot Welder to handle aluminum or stainless steel? |
| Q7: How do I choose the correct upgrade for my Senko 787E Plus Spot Welder? |
To choose the correct upgrade, consider the thickness and type of metal you want to weld, as well as your budget and welding needs. |
| Q8: Are there any safety precautions I should take when upgrading my Senko 787E Plus Spot Welder? |
| Q9: Can I perform the upgrades myself or should I hire a professional? |
If you are not experienced in electronics or welding equipment repair, it is recommended to hire a professional to perform the upgrades. |
| Q10: Will upgrading my Senko 787E Plus Spot Welder void its warranty? |
Check your warranty terms before performing any upgrades. Upgrading your welder may void its warranty, depending on the manufacturer's policies. |
| Rank |
Pioneers/Companies |
Description |
| 1. |
Miller Electric Mfg. Co. |
Developed the first AC/DC spot welder, expanding capabilities for thicker metals. |
| 2. |
Lincoln Electric |
Introduced advanced inverter-based technology, enabling more efficient welding of thicker metals. |
| 3. |
ESAB |
Created the first fully automatic spot welder, streamlining production for industries requiring thicker metal welding. |
| 4. |
Fronius International GmbH |
Pioneered advanced cold metal transfer (CMT) processes, ideal for welding thicker, high-strength metals. |
| 5. |
Bernard Welding |
Innovated with gun-style welders suitable for thicker metal applications, offering increased precision and control. |
| 6. |
T.W. Electrode Company (TWECO) |
Developed advanced electrode technology for spot welding, improving efficiency and quality on thicker metals. |
| 7. |
Air Liquide |
Introduced specialized shielding gases that enhance weld quality on thicker metals, optimizing the welding process. |
| 8. |
Kemppi Oy |
Pioneered digital welding equipment with advanced arc characteristics suitable for various thicker metal applications. |
| 9. |
Eastwood Company |
Developed affordable, high-quality spot welders designed for enthusiast and professional use on thicker metals. |
| 10. |
Potenteq Inc. |
Created specialized welding equipment accessories that improve the efficiency of spot welders for thicker metal applications. |
| Section |
Description |
| Overview |
The Senko 787E Plus Spot Welder is a popular choice among hobbyists and professionals for welding thin metals. However, its standard configuration may not be sufficient for thicker metals. This upgrade guide provides detailed technical specifications to modify the welder for thicker metal applications. |
| Required Components |
- High-current transformer (e.g., 10kVA, 48V secondary)
- Heavy-duty welding cables (e.g., 4/0 AWG, 10ft long)
- Welding electrode holders with thicker metal capability
- Heat sink and thermal interface material for the transformer
- High-power rectifier diodes (e.g., 100A, 400V)
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| Transformer Upgrade |
The standard transformer in the Senko 787E Plus has a limited current output. To upgrade, replace it with a high-current transformer that can handle thicker metals.
- Primary voltage: 120V or 240V (depending on your input power)
- Secondary voltage: 48V (nominal)
- Current output: minimum 500A peak
- VA rating: minimum 10kVA
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| Cable and Electrode Upgrade |
The standard cables and electrode holders may not be suitable for thicker metals. Upgrade to heavy-duty welding cables and electrode holders that can handle higher currents.
- Cable gauge: 4/0 AWG or lower (thicker)
- Cable length: minimum 10ft
- Electrode holder material: copper, brass, or other high-thermal-conductivity materials
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| Rectifier Upgrade |
The standard rectifier diodes may not be able to handle the increased current output. Upgrade to high-power rectifier diodes that can handle higher currents.
- Current rating: minimum 100A
- Voltage rating: minimum 400V
- Type: fast recovery or ultra-fast recovery
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| Heat Sink and Thermal Interface Upgrade |
Adequate heat sinking is crucial for the upgraded transformer. Ensure proper thermal interface material and a suitable heat sink are used.
- Heat sink material: aluminum, copper, or other high-thermal-conductivity materials
- Thermal interface material: thermal paste, tape, or other high-performance materials
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| Wiring and Safety Considerations |
Ensure all wiring is properly sized and insulated to handle the increased current output. Also, take necessary safety precautions when working with high-power electrical systems.
- Use proper gauge wiring (e.g., 10 AWG or lower)
- Insulate all connections and terminals
- Follow proper safety procedures for electrical work
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