Posted by John Olsen on 20/10/2016 01:47:38:
Incidently three phase welders of the older style, eg with just a transformer, actually only used two phases, with a transformer primary connected to them. The rod can only have single phase power going through it.
John
If you search for manuals etc on the Miller website you can see typical circuit diagrams for the old 3-phase transformer-based welding sources, such as the CP-300. Some models clearly show a 3-phase transformer and 6 diode rectifier bridge (page 10 in this example). The voltage variation is done by means of a variable tap on the secondaries. One advantage of a 3-phase transformer / rectifier arrangement is that the output voltage is smoother without the need for an output choke.
True, it's not always the case that they are 3-phase. If you want a controllable AC and DC source, it may be simpler and cheaper to have a single phase transformer and some form of regulator. The downside is somewhat sizeable load currents and an imbalanced load on the 3-phase network.
By way of example, I have a Miller 320A/BP welder (AC-DC TIG / MAW) from the 1970s that uses single phase (luckily for me). At 300A output it takes the best part of 70A from the mains. The control is done by means of a pair of enormous magnetic amplifiers (one for each half of the waveform) operating at the 50Hz mains frequency, feeding into a large DC choke forming an interleaved buck converter. This makes it the lowest frequency switched mode power supply (SMPS) I have worked on by quite a way. Excellent control down to 5A or so but the controls are complex and expensive. At the time it was pretty much state of the art. This control method would not work so well on a composite 3-phase waveform so is a good example of a high power single phase source. Nowadays, high frequency inverter sources make this kind of arrangement redundant. The decision to run from single or 3-phase is more down to convenience and acceptable mains loading.
Murray
Edited By Muzzer on 20/10/2016 11:19:09