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Tool Talk Discussion Forum

Ac welder to DC stabilizer coil size?

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JayWalt

04-30-2007 21:09:28




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Its wonderful that dad is the head electrician/maintenance guy at a stone quarry. He gets all kinds of neat stuff. He recently got some 400amp, 1400v diodes. We were going to make a convertor box for our ac stick welder. Through some reading (and general assuming), filter is a must for the true potential of a dc welder to be realized. Using caps was a bit out of the question, and better filtering is achieved through the use of an inductor. All of your good dc welder use them. Well dad brought home a buss choke from work. It is rated 170amp and .40mH. I dont have the foggiest as to what size should be used. we primarily use the welder on the 75 amp setting, sometimes the 90. Does anyone have ready access to a dc welder of simalar size and could see if their coil says what size it is, or does anyone have the knowledge to figure out what size coil is needed.

Thanks for any help.

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MarkB_MI

05-01-2007 18:58:56




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 Re: Ac welder to DC stabilizer coil size? in reply to JayWalt, 04-30-2007 21:09:28  
Well, assuming your lead resistance is around a tenth of an ohm, .4 millihenries would give you a time constant of around 4 milliseconds, which doesn't sound too bad. A full-wave rectified 60 Hz sine wave has a period of 8 milliseconds.

Believe it or not, too much filter can be as bad as too little. If the inductance is too high, it will make it hard to strike an arc; if the capacitance is too high it will cause big current spikes in the transformer.

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JayWalt

05-01-2007 20:58:05




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 Re: Ac welder to DC stabilizer coil size? in reply to MarkB_MI, 05-01-2007 18:58:56  
thanks mark.



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dan hill

05-01-2007 15:50:46




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 Re: Ac welder to DC stabilizer coil size? in reply to JayWalt, 04-30-2007 21:09:28  
I found that capacitors raised the open circuit voltage to 94 volts.Too high ,80 volts is maximum.I wound the reactor with two # 6 fibreglas ins. wire in paralell to make the reactor.You can buy a ready made reactor for 50.00, it is wound with flat wire, very few turns.Hi open circuit volts makes arc starting easy, but shock hazard increases.Diodes should be bypassed with hi volt .o2 caps.I spent 100.00 building the converter.Had some parts on hand..

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buickanddeere

05-01-2007 11:38:03




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 Re: Ac welder to DC stabilizer coil size? in reply to JayWalt, 04-30-2007 21:09:28  
Capacitors of rated voltage or better can't hurt placed after the diodes. Unless the TX secondary is center tapped, a bridge rectifier using four diodes will be required. The inductive coil goes in series with a cable going to or returning from the arc.



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