Arc Welding Machine

This ebook is complete guide to make a welding machine of different capacities. It covers transformer
design and the most important the control circuit to control the weld energy.

Though not to difficult to under stand but a little technical knowledge about electricity; transformer and
knowledge about welding machines in general is essencial. This is professional welding machine
manufacturing guide.

1. 150 amps machine

Steel Lamiination ---- Size No.8 (This is a standard E & I size)

Stack ---- 10 cms

25mm

25mm 25mm
50mm

Priimary winding for 110 volts input ---86 turns ---10 swg

for 230 volts iinput 180 turns 12 swg

Secondary wiinding 30 turns 5 swg

Open circuit voltage on secondary side 37 to 39 volts

2. 250 amps machine

Steel Lamiination Size 8B

Stack 10 cms
235mm
38mm

38mm 38mm
155mm 75
mm

235 mm ....2
 -2-

Primary winding: for 110 volts input 58 turns 9 gauge

for 230 volts 120 turns --11 gauge

for 400 volts 214 turns 14 gauge

Secondary windiing - 34 turns 1 gauge

this transformer will give an out put of 65 volts (Open circuit voltage)

3. 400 amps machiine

Steel laminatiion : 23 cm x 7.5 cm strip

19 cm x 7.5 cm strip

Stack 13 cm

Primary Primary

Secondary Secondary

Primary wiindiing ---- 220 volts 88 turns 8 gauge

( 2 coils of 44 turns each connected iin series)

400 volts iinput 164 turns 10 gauge

(2 coils of 82 turns each connected in seriies)

Secoondary wiinding 32 turns ( 2coils of 16 turns each connected in series)

Thiis transformer will have output of 80 volts (OCV)

I am not discussing the winding technic and transformer making process as it is not in scope
of this paper. I presume the reader has basic knowledge of transformer making. You can visit
these sites to know more.
Http://sound.westhost.com/xfmr.htm www.allaboutcircuits.com/vol_6/chpt_4/3.html

The transformer mentioned can be made using other size of steel lamination. If the standard
size lamination is not available in your part of the world; get back to me and i will give you
other options.

...3
 -3-

Block Diagram

Secondary feedback

Control pot

Stable adjustable
output for clean
1 phase or 2 phase WEC welding

Transformer
Welding Energy Controller: This circuit is simple to understand. The
mains supply voltage is dropped by using a half watt resistor (180K) and
applied to Pc814 to sense zero crossing. The same mains voltage is used to
make a power supply using a 15 watt resistor(10k), diode, zener and capacitor.

Lm555 is wired as monostable. At every zero-crossing the timer is triggered

and the output pin 3 remains high for a preset period set by the 10K pot.

The feedback circuit rectifies the Open circuit voltage of the welding
transformer. The rectified voltage is applied to Pc817 thru a zener. When
the OCV is above the zener voltage it switches on Pc817 and in turn brings
the resistor Rfeed in to the main circuit and in parallel to the 10 k pot. The
total resistance value drops and so more energy is available at the welding
output. As soon as the arc is established, the OCV drops below the zener
voltage switching of Pc817 and in turn Rfeed gets out of circuit.

JP shown on the schematic is were you connect a fix temperature thermostat

(100 or 105oC) and stick it on the primary winding. If and when the
winding temperature reaches 100oc the thermostat cuts and in turn cuts
supply to MOC 3052. LED glows indicating overheat.

Power Device: BTA41 mounted on a Al plate 100 125 mm -6mm thick

can handle 32 amps at 230 volts without any problems. You need to connect
2 BTA41 in parallel for a 250 and 400 amps machine. Mount the 2 BTA41 on
a 100 x 200 mm - 6mm Al plate.