INTRODUCTION

Welding Transformer
Welding Transformers are used in AC machines to
change alternating current from the power line into a low-
voltage, high amperage current in the secondary winding.
A combination of primary and secondary taps on
the welding transformer are commonly used to provide a
macro adjustment of the welding current, as well as
adjustment of secondary voltage. Transformer ratings for
AC machines are expressed in KVA (kilovolt-amperes)
for a specified duty cycle. This duty cycle rating is a
thermal rating, and indicates the amount of energy that the
transformer can deliver for a stated percentage of a
specific time period, usually one minute, without
exceeding its temperature rating. The RMS Short Circuit
Secondary Current specification indicates the maximum
current that can be obtained from the transformer. Since
heating is a function of the welding current, this
parameter gives an indication of the thickness of the
materials that can be welded.
A welding transformer is a step down
transformer that has thin primary winding with a large
number of turns and its secondary has more area of cross-
section and less number of turns ensuring less voltage and
very high current in the secondary. The welding
transformer reduces the voltage from the source voltage to
a lower voltage that is suitable for welding. Usually
between 15 and 45 volts. The secondary current is quit
high and it may be typically 200A to 600A, but it could
be much higher. The secondary may have several taps for
adjusting the secondary voltage to control the welding
current. The taps are typically connected to a several
high-current plug receptacles or to a high-current switch.
One end of the secondary is connected to the welding
electrode, whereas the other end of the secondary is
connected to the welding electrode, whereas the other
end is connected to the pieces to be welded .If any high
current flows, heat is produced due to the contact
resistance between the electrode and the pieces to be
welded. The generated heat melts a trip of the electrode
and the gap between the two pieces is filled.
The impedance of welding transformer may be higher
than that of the impedance of a general purpose
transformer. The impedance of welding transformer may
play a role in the process of establishing an arc and
controlling the current. Large welding transformers are
most likely to be designed for three phase input. There are
many smaller transformers that are designed for single
phase input.

Electrodes
An electrode is an electrical conductor used to
make contact with a nonmetallic part of a circuit (e.g.
a semiconductor, an electrolyte, a vacuum or air).
The word was coined by William Whewell at the
request of the scientist Michael Faraday from
two Greek words: electron , meaning amber (from
which the word electricity is derived), and hodos, a
way. The electrophore, invented by Johan Wilcke,
was an early version of an electrode used to
study static electricity.
In arc welding, an electrode is used to conduct
current through a workpiece to fuse two pieces
together. Depending upon the process, the electrode
is either consumable, in the case of gas metal arc
welding or shielded metal arc welding, or non-
consumable, such as in gas tungsten arc welding.
For a direct current system, the weld rod or stick
may be a cathode for a filling type weld or an anode
for other welding processes. For an alternating
current arc welder, the welding electrode would not
be considered an anode or cathode.

Ammeter
An ammeter (from Ampere Meter) is a measuring
instrument used to measure the current in a circuit.
Electric currents are measured in amperes (A),
hence the name. Instruments used to measure
smaller currents, in the milli ampere or microampere
range, are designated as milli ammeters or micro
ammeters. Early ammeters were laboratory
instruments which relied on the Earth's magnetic
field for operation. By the late 19th century,
improved instruments were designed which could be
mounted in any position and allowed accurate
measurements in electric power systems. It is
generally represented by letter 'A' in a circle.

Volt meter
A voltmeter is an instrument used for
measuring electrical potential difference between
two points in an electric circuit. Analog voltmeters
move a pointer across a scale in proportion to the
voltage of the circuit; digital voltmeters give a
numerical display of voltage by use of an analog to
digital converter.
A voltmeter in a circuit diagram is represented by the
letter V in a circle.
Voltmeters are made in a wide range of styles.
Instruments permanently mounted in a panel are
used to monitor generators or other fixed apparatus.
Portable instruments, usually equipped to also
measure current and resistance in the form of
a multimeter, are standard test instruments used in
electrical and electronics work. Any measurement
that can be converted to a voltage can be displayed
on a meter that is suitably calibrated; for example,
pressure, temperature, flow or level in a chemical
process plant.
General purpose analog voltmeters may have an
accuracy of a few percent of full scale, and are used
with voltages from a fraction of a volt to several
thousand volts. Digital meters can be made with
high accuracy, typically better than 1%. Specially
calibrated test instruments have higher accuracies,
with laboratory instruments capable of measuring to
accuracies of a few parts per million. Meters
using amplifiers can measure tiny voltages of micro
volts or less.
Part of the problem of making an accurate voltmeter
is that of calibration to check its accuracy. In
laboratories, the Weston Cell is used as a standard
voltage for precision work. Precision voltage
references are available based on electronic circuits.