CHAPTER 1

ARC WELDING POWER SOURCES

WELDING POWER SOURCE

-ARC-

FUSED DISCONNECT SWITCH (OPEN)

CONTROLLING

--

CHARACTERISTIC

CHASSIS GROUND CONNECTION

--

ELECTRICAL CONNECTION
MECHANICAL STRUCTURE AND CHASSIS

Figure 1.1-Basic

Elements of an Arc Welding Power Source

requirements. Special features can also be included such constant. Constant-current power sources are also known
as remote control, high-frequency stabilization, current- as variable-voltagepower sources, and constant-voltage
pulsing capability, starting and finishing current versus power sources are often referred to as constanttime programming, wave balancing capabilities, and potential power sources. These fast-response, solidline-voltage compensation. Conventional magnetic con- state power sources can provide power in pulses over a
trols include movable shunts, saturable reactors, mag- broad range of frequencies.
netic amplifiers, series impedance, or tapped windings.
Solid-state electronic controls may be phase-controlled
silicon-controlled rectifiers (SCRs) or inverter-controlled
semiconductors. Electronic logic or microprocessor cir- CONSTANT-CURRENT ARC WELDING
POWER SOURCES
cuits may control these elements.
Figure 1.1 shows the basic elements of a welding
The National Electrical Manufacturers Association
power source with power supplied from utility lines.
(NEMA)
standard Electric Arc- Welding Power Sources,
The arc welding power source itself does not usually
EW-1:
1988
(R1999), defines a constant-current arc
include the fused disconnect switch; however, this is a
power
source
as one which has means for adjusting
necessary protective and safety element.
the
load
current
and which has a static volt-ampere
An engine-driven power source would require elecurve
that
tends
to
produce a relatively constant load
ments different from those shown in Figure 1.1. It
current.
At
a
given
load current, the load voltage is
would require an internal combustion engine, an engine
responsive
to
the
rate
at which a consumable metal
speed regulator, and an alternator, with or without a
electrode
is
fed
into
the
arc. When a tungsten electrode
rectifier, or a generator and an output control.
Before the advent of pulsed current welding pro- is used, the load voltage is responsive to the electrodecesses in the 1 9 7 0 ~
welding
~
power sources were com- to-workpiece distance.lg2 These characteristics are
monly classified as constant current or constant
voltage. These classifications are based on the static 1. National Electrical Manufacturers Association (NEMA), 1988
(R1999),Electric Arc-Welding Power Sources, EW-1: 1988, Washingvolt-ampere characteristics of the power source, not the ton,
D.C.:National Electrical Manufacturers Association, p. 2.
dynamic characteristic or arc characteristics. The term 2. At the time this chapter was prepared, the referenced codes and other
constant is true only in a general sense. A constant- standards were valid. If a code or other standard is cited without a date
voltage output actually reduces or droops slightly as the of publication, it is understood that the latest edition of the document
arc current increases, whereas a constant-current out- referred to applies. If a code or other standard is cited with the date of
publication, the citation refers to that edition only, and it is understood
put gradually increases as the arc length and arc voltage that any future revisions or amendments to the code or standard are not
decrease. In either case, specialized power sources are included; however, as codes and standards undergo frequent revision,
available that can hold output voltage or current truly the reader is advised to consult the most recent edition.