Power source confusion

[Migmaster-ish]

Does anybody on here know the difference between a transformer power source and a "step switch" power source?

I'm currently running inverter welders and struggling with reliability issues due to dust levels in the workshop (unfortunately the nature of the job)... We never had problems with transformers and I'm trying to go back down that road. Although the British government have restricted size of transformer welders to 300amp for some reason and this just isn't big enough for what we do. And I'm struggling to find anybody selling a decent one that knows anything about their own equipment when I ask for details. All I keep getting told is it's neither inverter or transformer and I'm getting slightly confused.

 

[voipio]

If a "step switch" welder was a thing, then a google search would return lots of results. It doesn't, which suggests that "step switch" might just be someone's name for an inverter welder, since these use switching transistors as part of the power regulation and delivery circuits. I've not seen any marketing for any "step switch" welders.

In cases where dust is a real issue, one possible solution might be to have a regular maintenance schedule, where dust removal internally is written in as part of the maintenance process. Another might be to add a filtered fan assembly over the main air inlet to the welder, or to put the welder into a cabinet receiving filtered air.

The perceived "trouble" with transformers operating off a 50 or 60Hz incoming mains supply, is that they do have losses, even when they're connected to the mains, but not doing any electrical work. So the powers that be have decreed the phasing out of transformers in order to save the planet. Inverter circuits have losses too, but these tend to be lower than transformer based devices.

 

[skotl]

Does anybody on here know the difference between a transformer power source and a "step switch" power source?

I'm currently running inverter welders and struggling with reliability issues due to dust levels in the workshop (unfortunately the nature of the job)... We never had problems with transformers and I'm trying to go back down that road. Although the British government have restricted size of transformer welders to 300amp for some reason and this just isn't big enough for what we do. And I'm struggling to find anybody selling a decent one that knows anything about their own equipment when I ask for details. All I keep getting told is it's neither inverter or transformer and I'm getting slightly confused.

Welcome to the forum

Agree with what voipio said - you're presumably talking about inverter welders, which have a lot of electronics and don't take kindly to dust, especially if that dust is carrying iron filings.
Plenty (probably most) fab shops will be using inverter welders nowadays so you just need to take care about minimising dust, especially grinder dust, and give them a regular swish with a vacuum.

 

[morssdn]

I would have said a “step switch” welder would be a multi tapped transformer mig like a basic Clarke ie a transformer welder.

 

[minimutly]

If a "step switch" welder was a thing, then a google search would return lots of results. It doesn't, which suggests that "step switch" might just be someone's name for an inverter welder, since these use switching transistors as part of the power regulation and delivery circuits. I've not seen any marketing for any "step switch" welders.

In cases where dust is a real issue, one possible solution might be to have a regular maintenance schedule, where dust removal internally is written in as part of the maintenance process. Another might be to add a filtered fan assembly over the main air inlet to the welder, or to put the welder into a cabinet receiving filtered air.

The perceived "trouble" with transformers operating off a 50 or 60Hz incoming mains supply, is that they do have losses, even when they're connected to the mains, but not doing any electrical work. So the powers that be have decreed the phasing out of transformers in order to save the planet. Inverter circuits have losses too, but these tend to be lower than transformer based devices.

They have bigger losses when they go bang...

 

[Nix2]

I would have said a “step switch” welder would be a multi tapped transformer mig like a basic Clarke ie a transformer welder.

True, most often a welder/semi-automatic welder is simply a transformer plus a step switch (range switch), but there are also welders/semi-automatic (with a large) transformer and thyristor control (potentiometer, not a step switch)

 

[More Amps]

I remember reading recently, but can't remember where, or indeed how true/reliable it is, but there was mention that transformer based machines can still be made if their intended use is personal and not commercial... If that is true, then it might be worth speaking to Technicalarc (technicalarc.co.uk) and see just what's possible as they are the only people I know of who build machines to order and could be in a position to help.

 

[Munkul]

I would have said a “step switch” welder would be a multi tapped transformer mig like a basic Clarke ie a transformer welder.

bingo.
Most (but not all) transformer MIGs are step switched for voltage, and all step switched MIGs are transformer MIGs (that i've seen anyway)

out of interest, what brands are failing? Cheap ones or expensive ones like Kemppi, Lorch etc?
Most high quality ones seperate the electronics from the cooling system so dust is not really an issue...

theres not many truly good welding suppliers any more, most of the sales guys know very little... Try express cutting and welding, finbarr is very good...