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AC welders derive their name from the fact that their output is generally a sine wave at the same frequency as the power line. These systems extract energy directly from the power line during the weld cycle, which means the facility power must be well regulated and capable of delivering the required energy.
Some AC welders — including AMADA WELD TECH AC welders — include line voltage compensation to automatically adjust for fluctuations in incoming power.
In its simplest form, an AC welder consists of a welding transformer that steps down line voltage (typically 480 to 100 volts) to a welding voltage in the range of 2 to 20 volts.
The welding current flowing through the transformer secondary and the connected load is very high, typically ranging from 10 amps to more than 100,000 amps. This current is applied for short durations, generally between 0.001 and 2 seconds. AC welders can operate at rates of up to 5–6 welds per second, depending on the application.
AC welding systems are generally composed of three primary elements:
The transformer converts alternating current from the power line into low-voltage, high-amperage current in the secondary winding.
Primary and/or secondary taps are commonly used to provide macro adjustment of welding current and secondary voltage.
Transformer ratings are expressed in KVA (kilovoltamperes) at a specified duty cycle. The duty cycle represents a thermal rating — the amount of energy the transformer can deliver during a stated percentage of time (typically one minute) without exceeding its temperature limit.
The RMS Short Circuit Secondary Current specification indicates the maximum current obtainable from the transformer. Since weld heating is directly related to welding current, this parameter provides an indication of the material thickness that can be welded.
Recent developments in AC welding include constant current feedback control at line frequency (50 or 60 Hz). This feature is particularly useful for welds longer than five cycles (approximately 82–100 milliseconds), as it automatically adjusts power supply parameters to maintain stable welding performance.
AC welders are characterized by:
AC welding systems are commonly used in applications such as:
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