Re: [TCML] pole pig ballasting

[FIFTYGUY@xxxxxxx]

In a message dated 8/31/08 11:36:53 P.M. Eastern Daylight Time,  
rja12@xxxxxxxxxxx writes:

>                   I'm looking at two Thunderbolt welders for ballasting my  

>125KV X-ray transformer. One is a clean, older model with the shunt  control 

>crank on the top. The other is a newer Thunderbolt XL with the  shunt 
control 

>crank on the lower front. Any preference as to which one I should  go for?



I looked at repair parts for Miller  Thunderbolts a few months ago. I was 
trying to see if it was economical to  convert ours to 480V instead of 240V, but 
it was cheaper and easier to trade  it in for a different welder. So I'm 
familiar with the Thunderbolt  construction.
    Both models work exactly the same way, with a  mechanically adjustable 
core shunt. The transformer assemblies even look  almost identical between the 
models, except one mounts vertically and the  other horizontally. Provided the 
two welders are of the same input and output  ratings they should be 
electrical twins. I believe the change to a front  adjusting handle was a convenience 
feature (we've got a stack of rod cans on  top of our front-crank Thunderbolt 
XL at work).
 
>   Just how is the xfmr designed to allow a variable gap  
>for current control?


    Turning the crank operates a screw  that slides a separate core piece in 
and out of the welder's power  transformer. The core moves in a plastic guide, 
and IIRC everything is pretty  much contained in the transformer assembly 
(all you would need is the crank if  you removed the power transformer from the 
welder). 
 
 
    Here's the owner's manual for a typical  top-crank style:
 
    _http://www.millerwelds.com/om/o316g_mil.pdf_ 
(http://www.millerwelds.com/om/o316g_mil.pdf) 
 
 
    and the manual for the newer side-crank  style:
 
    _http://www.millerwelds.com/om/o316s_mil.pdf_ 
(http://www.millerwelds.com/om/o316s_mil.pdf) 
 
    
    The manuals include schematics and parts diagrams,  so they should be 
helpful to you.
 
-Phil LaBudde

Center for the Advanced Study of Ballistic  Improbabilities



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