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Re: [TCML] Welding Transformer As Ballast or Choke



I purchased an inexpensive arc welder from Sears which had a retractable transformer core to adjust the current. With the welder output shorted I could adjust the pole pig current from 18 to 60 amps.
Dave

At 07:21 PM 6/5/2018, you wrote:
Content-Transfer-Encoding: base64Dan,

A shorted welding transformer stores energy in an expanding magnetic field which is then returned to the power circuit as the sine wave of the input power waveform decays, kinda like compressing a spring. When you relieve the pressure on the spring, the spring pushes the energy back into your system.
If you use a resistor, the resistor converts the 
energy to heat, which is lost, and not returned 
to the system.  This is much less efficient.  It 
would provide ballasting, at the expense of a 
lot of waste heat.  Any resistance in the 
ballast components will generate waste heat, so 
you want to minimize that as much as possible.
If you want an easily and infinitely adjustable 
ballast, you would use a saturable 
reactor.  This is a special transformer which 
would perform the same function as a shorted 
welder, but in which the permitted current is 
controllable by a small low voltage DC current 
applied to a special set of control windings.
Saturable reactors provide nice control for TC 
systems, but ones big enough to effectively 
control a pole pig can easily weigh half a ton, 
and are usually very expensive, unless you can find a surplus unit for cheap.
Last spring, I bought an assembly nearly 
identical to the following one for $130 for the 
copper scrap value, but it cost me $580 in 
shipping fees to get it to my friend's factory 
shipping dock. "Some day" I hope to build a coil 
big enough to put it to effective use.
https://www.ebay.com/itm/40-KVA-20-AMP-460-VOLT-HUNTERDON-SATURABLE-CORE-REACTOR-TRANSFORMER-S-1207-1/292572873068

The reactor that was in it looks just like the following one, but is mine "only" 52 KVA rated. I think there is a typo in the listing. The rating should be more like 60 KVA, not 600. I would speculate that a 600 KVA core would likely weigh several tons.
https://www.ebay.com/itm/NEW-Hunterdon-Saturable-Core-Reactor-Transformer-600KVA-60Hz-WE-1097-R-C98R2/282780054079

(I have no connection to either seller.)

You can buy a lot of welders to short out for $4,800 plus shipping.

To understand saturable reactors, look up "magnetic amplifiers" in Wikipedia.

Dave


On 6/5/2018 11:22 AM, Daniel Kunkel wrote:
As already pointed out, for a current limiting ballast transformer, the
secondary coil will be shorted out, and the primary will be in series with
HØY??£â?÷vWfW"Â??fR&VVâvöæFW ing what would happen if you put a (variable)
resistor on the secondary side of the ballast transformer (instead of a
dead short). I wonder if this would give you some degree of variable
Ý\??[?[Z][?Âg&öÒÆÂ×?&VF?ng, it seems like the best current
[Z][?È\Ù\È?Õ@nductance and resistance...so I wonder if resistance
Àcated in this location would work.
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