[TCML] How to use an arc welder as a ballast?

[David Rieben]

Hi Scot,

Ed Wingate uses 2 paralleled welders to run his big maggie
(I believe their both Lincoln 225 amp AC arc welders)
Here is the best pic that I could find of his setup, off hand:
http://www.tb3.com/tesla/ratcb2005/pages/IMG_4108.html
(You can barely see one of the welders behind the pole pig
on the left.) I'm sure Ed could further commnet on this but
I don't recall him stating that paralleling the 2 welders was
a big deal. I believe Cameron Prince has also tried a 2
welder ballast setup so he may also have something to add.

David


----- Original Message ----- 
From: "bunnykiller" <bunnikillr at cox.net>
To: "Tesla Coil Mailing List" <tesla at pupman.com>
Sent: Monday, May 05, 2008 7:05 AM
Subject: Re: [TCML] How to use an arc welder as a ballast?


> Hey Marcus...
>
> In theory it seems possible, but in real life there may be some 
> differences between the welders, even as small as they are, they can 
> become problematic. As in paralleling variacs, a  balancing( paralleling) 
> choke may be needed to even out the current flow between the 2 welders. 
> The potential problem I see with this type of set up is that you would 
> have to turn off the system to adjust the welders current levers( 
> controls) unless you can find a way to mechanically link the current 
> controls of both machines. Adjusting the welders one at a time while the 
> coil is running would most likely cause one welder to carry the major 
> portion of the current untill the second welder is brought into balance 
> with the other welder.
>
> Scot D
>
>
>
> marcus masencup wrote:
>
>>Thanks for the great reply, bunnykiller! I have also read that I can run 
>>two
>>similar welder in parallel together and increase the ability of the
>>ballast this way. Would that work to allow me to push the pig harder 
>>without
>>hurting the welders? Thanks again!
>>
>>On Sun, May 4, 2008 at 10:08 PM, bunnykiller <bunnikillr at cox.net> wrote:
>>
>>
>>>Hey Marcus...
>>>
>>>First and foremost you must consider the size and capacity of the welder
>>>to be used "as a ballast". second thing to consider is the type of wire 
>>>used
>>>in the welder itself, aluminum wiring wont last too long, copper wiring 
>>>on
>>>the welders transformer primary will have a better life span.
>>>as for the wiring technique, the 2(3) leads that power the welder will be
>>>the ones used to "ballast" the piggie. General concensus calls for wiring
>>>the welder as such....
>>>
>>>the ground lead(green)of the welder goes to ground of the receptical on
>>>the source, the black lead ( hot wire from the source/recepticle) 
>>>attaches
>>>to the black lead of the welder, the red ( most commonly used in 240VAC 
>>>,,,
>>>the other half of the dual 120vac) of the welder attaches to one of the
>>>inputs of the piggie, the other input of the piggie attaches to the red
>>>output of the source/recepticle. Basically the welder primary is in 
>>>series
>>>with the input to the piggie.
>>>
>>>short out the secondary side of the welder ( in other words stick a short
>>>length of welding lead between the welders ground and welding lead 
>>>output)
>>>
>>>start with the welder set on minimal current setting and slowly work your
>>>way up to higher current levels via the current control on the welder to
>>>increase current thru the piggie. WATCH for glowing inside the welder,
>>>smoke, or rather obnoxious humming noises, if it begins to throw sparks,
>>>shut it down and begin looking for another welder or a really big
>>>transformer core to wind your own ballast.
>>>
>>>IF you have the welders original paperwork, see what the DUTY CYCLE is...
>>> this is a rating as to how long the welder can remain on for a maximim
>>>amount of time before it needs a cool down period. When a welder is used 
>>>as
>>>a ballast, the welder "thinks" it is in its welding status since the 
>>>welding
>>>leads are shorted ( in welding mode)
>>>If you can, find a scrap yard or such that will have a 10 - 20 KVA rated
>>>step down transformer ( 480 to 240) you will have a great core to rewind 
>>>for
>>>a ballast. Usually they are a bit heavy but can handle the requirements 
>>>of
>>>ballasting a piggie...
>>>
>>>Scot D
>>>
>>>
>>>
>>>marcus masencup wrote:
>>>
>>>  I am stepping up to pole pigs after years of using NST's. I have read
>>>
>>>>everything I can find online and for me it seems that an arc welder is
>>>>the
>>>>easiest way to add the current limiting and ballast I need to run the
>>>>10kva
>>>>pole pig I have. What I can't find is how I need to wire the arc welder
>>>>up
>>>>with the pole pig? Any help on how to wire this would be great, thanks!
>>>>_______________________________________________
>>>>Tesla mailing list
>>>>Tesla at www.pupman.com
>>>>http://www.pupman.com/mailman/listinfo/tesla
>>>>
>>>>
>>>>
>>>>
>>>_______________________________________________
>>>Tesla mailing list
>>>Tesla at www.pupman.com
>>>http://www.pupman.com/mailman/listinfo/tesla
>>>
>>>
>>_______________________________________________
>>Tesla mailing list
>>Tesla at www.pupman.com
>>http://www.pupman.com/mailman/listinfo/tesla
>>
>>
> _______________________________________________
> Tesla mailing list
> Tesla at www.pupman.com
> http://www.pupman.com/mailman/listinfo/tesla