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Tool Talk Discussion Forum

welder resistors

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bil b va

03-02-2007 15:21:12




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i have a onan welder that uses metal strip resistors to the different taps . one of these resistors is no longer availiable . does anyone know how i can duplicate this resistor ? motor runs good and everything works . just these strip rsistor break from the vibration . hate to junk it . 200 amp dc machine .




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larry in tn

03-03-2007 02:40:14




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 Re: welder resistors in reply to bil b va, 03-02-2007 15:21:12  
You might even try spot welding the two halves together to repair the resistor. Strip metal shunts/resistors such as yours have a very low resistance. I've made them from regular banding iron strap material.



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dds-inc

03-02-2007 19:22:56




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 Re: welder resistors in reply to bil b va, 03-02-2007 15:21:12  
i agree with bus driver but keep in mind that you have to use a resistor about the same size. They have to be the same size so that the current will not burn up the resistor.



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Bus Driver

03-02-2007 15:33:45




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 Re: welder resistors in reply to bil b va, 03-02-2007 15:21:12  
Resistors are "generic" in the sense that the same value in Ohms and in the wattage rating make them electrically and functionally equal. Finding one that will physically mount may, or may not, be easy. If the above values are known, replacement should not be difficult. If unknown, the resistors for the next lower and next higher settings can be measured for Ohms value with a multi-meter and the Ohms value of the burned-out one can be approximated by interpolating between the value of the other two. A size comparison will help determine the wattage rating of the resistors.

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bil b va

03-02-2007 20:05:57




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 Re: welder resistors in reply to Bus Driver, 03-02-2007 15:33:45  

thanks . you have given me food for thought . i should be able solder the two pieces together and get a accurate resistance measurment . my next challenge is what to use for the replacment . these resisistors are like ribons about 3/4 in. wide .010 to .030 thick depending on location and about 24 in long folded in a loop . i suspect the design in for heat disapation . a new one looks similar in color to a heating element . may even try brazing/silver soldering the two parts together .

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Gerald J.

03-04-2007 14:41:56




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 Re: welder resistors in reply to bil b va, 03-02-2007 20:05:57  
Probably IS made of Nichrome ribbon. To make a resistance lower than if it was made of wire and higher than if it was made of a strip of copper. I doubt your ohmmeter is going to show a resistance other than zero.

Gerald J.



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Frank in Florida

03-03-2007 20:01:08




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 Re: welder resistors in reply to bil b va, 03-02-2007 20:05:57  
Resistors of large wattage and low resistance can be made from nichrome wire that is normally used for heating elements. McMaster Carr likely stocks this.



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