Transformer Basics

Electric transformer
(courtesy of Aftek EHS)

Transformers are composed of an iron core ring wrapped in coils. One coil is connected to an AC input voltage and is called the primary coil. The other coil is connected to an output circuit with the load resistance, and is called the secondary coil.

The two coils are well insulated from each other and do not form a physical electrical connection. This gives a transformer its unique electricity altering properties. Transformers can either step up or step down a voltage.

In a step down transformer, the number turns in the primary coil is greater than the number of turns in the secondary coil step up transformer the number of turns in the secondary coil is greater than the number of turns in the primary coil. The constantly changing current driven by an alternating voltage source induces a changing magnetic field in the core of the transformer.

The magnetic field created by the alternating current in the primary coil generates the flux in the transformer core. The secondary coil converts the flux back into current flow and produces a voltage at the load, or resistance, in the secondary circuit.

If there are fewer coil turns on the secondary then on the primary, this is called a step down transformer. The resulting voltage in the secondary circuit will be less than the primary.

In this example we have 20 turns on the primary coil and 10 turns on the secondary coil. To determine the decrease in voltage occurring in this step down transformer, we can use a simple ratio formula. This formula simply states that the secondary voltage to primary voltage ratio, is the same as the secondary coil to primary coil turn ratio. Rearranging the formula and then dividing 10 turns by 20 turns, we get .5 multiplied by 120 V. This results in a calculated step down voltage of sixty volts.

HofoilEHS - Your Preferred Source for Pre and Post Weld Heat Treating

HotfoilEHS is a premier manufacturer of pre weld and post weld heat treating equipment. EHS manufactures and sells pre and post-weld heat treating equipment including power consoles, ceramic mat heaters, thermocouple attachment units, pin welders, Brinell testers, Poldi hardness testers, thermocuple wire, insulation, and accessories.

The below video is a little shameless, self promotion.

Power consoles are standardly offered in 6, 9, 12, 18, and 24 zone configurations with a variety of control and recording systems.

Twin heating modules, with and without recorders, and optional ramping controllers are available from EHS.

For special projects, EHS can provide mineral insulated (MI) heating circuits designed into a blanket-type layout, using clips to attach the circuits to a wire mesh in a configured pattern. The circuits are CSA and FM Approved for hazardous and non-hazardous areas.

EHS also offers short or long term rentals on power consoles, temperature recorders, and ceramic mat heaters along with complete support and training services.

EHS engineers, designs, and manufactures proven systems to effectively complete any project more efficiently than competitive systems, while staying within budget. Years of application experience and successful installations have produced thousands of happy customers.

Ceramic Heater Pads for Weld Preheating and Post Weld Heat Treating

Welding ceramic pad heater
(courtesy of HotfoilEHS)

The goal of preheating and post weld (PWHT) heating is to maintain temperature between weld passes and to uniformly control changes in target temperatures. By properly achieving, maintaining, and then cooling weld temperatures, you lower weld stress, distortion, reduce shrinkage stress and allow unwanted hydrogen to escape.

It is very important to understand the material characteristics of the metals being welded, and know minimum and maximum preheat temperatures, particularly in tempered steels.

For most preheating, post heat treating, and interpass heating, precise temperature control isn't required. Its more important to maintain a minimum temperature, and stay within an acceptable range during the actual welding process, as well as during cool down.

Exceptions are with tempered steels. Tempered steels have already been heat treated at the steel mill and applying too much preheat can alter that tempering. In these cases, proper set point, temperature limiting, and temperature ramp rate of the welded part is critical.

Use of Ceramic Heater Pads

Resistance heating pads are constructed of ceramic beads strung on nichrome wire. These resistance heating elements accurately raise the workpiece temperature to the proper temperature before, during, and after welding, complying with recommended preheat, interpass, and PWHT practices. These semi-flexible ceramic heater pads, with their interlocking beads and high temperature wire, allow for a fit conforming to the shape of the workpiece, and are capable of temperatures up to 1,850 degrees F. Ceramic mat (pad) heaters have an additional benefit in that they don’t have to be moved during welding.

Recorders and controls used for
welding preheat and post heat.

Electronic temperature controllers use several thermocouples spot welded to the workpiece to monitor and regulate the actual part temperature throughout the operation. Many times the electronic controllers have ramping or temperature profiling capabilities, so that heat-up and cool-down can be carefully controlled. Recorders are often used to produce a record of the temperature profiles over time before, during, and after welding. This is important when welding jobs require careful documentation.

An average application is as follows: the heater pad is wrapped around the workpiece, and insulation is applied to the weld joint and the temperature controller is set. Once preheat temperature is achieved, a welder removes the insulation and starts their work. After the weld, the ceramic heaters can be placed over the weld and the controllers can be reset for proper PWHT.

Replacing the Print Head on AH4000 Recorder

AH400 Recorder

The AH4000 multi-channel recorder is used on HotfoilEHS power consoles to monitor and record pre weld, soak, and post weld heat treating. One of the most common questions asked is how to replace the print head.

The video below provides visual, step-by-step instructions.

10 Million BTU Burner for Custom Designed Heat Treating Furnace

Custom heat treating furnaces are designed for the tempering of metals. These furnaces can be electrically heated, or gas heated, depending on the energy source available. Tempering is defined as (from Wikipedia):

"Tempering is a heat treatment technique applied to ferrous alloys, such as steel or cast iron, to achieve greater toughness by decreasing the hardness of the alloy. The reduction in hardness is usually accompanied by an increase in ductility, thereby decreasing the brittleness of the metal. Tempering is usually performed after quenching, which is rapid cooling of the metal to put it in its hardest state. Tempering is accomplished by controlled heating of the quenched work-piece to a temperature below its "lower critical temperature". "

The video below shows the testing of a 10 million BTU ratio air burner designed for a custom heat treating furnace used to pre-stress large metal components prior to welding. Hotfoil-EHS manufactures complete furnace systems using OEM burners and in-house developed control systems.

For more information, contact:

Hotfoil-EHS
2960 East State Street Ext.
Hamilton, NJ 08619
Phone # 609.588.0900
Fax # 609.588.8333
Email: dap@hotfoilehs.com

Self Regulating Heating Cable

Self regulating heating cable

Self-regulating heating cables automatically adjust their power output to compensate for temperature changes. The outer jacket, braid, and inner jacket provide mechanical, chemical, and electrical protection. The magic happens in the conductive core that surrounds the two parallel conductors. As the ambient temperature drops, the core contracts microscopically, and the number of electrical paths through the core increases, more heat is produced. Conversely, as the ambient temperature rises, the core expands and has fewer electrical paths, and less heat is produced. At a certain temperature, almost all the electrical paths are disrupted and power output is close to zero. A self-regulating heating cable adjusts its power output along its entire length. That's what makes it a safe and reliable solution for many applications.

Self-regulating cable is flexible, and is much easier than constant wattage cable because it can be cut-to-length in the field, terminated, and (if needed) overlapped without fear of burnout. This is very valuable in areas where complex piping systems exist with many valves, tanks and vessels.

As with any heat tracing cable, proper wattage requirements need to be calculated. In order to properly calculate wattage, the following information must be known:

• Pipe size and material
• Insulation type and thickness
• Maintain temperature
• Minimum ambient temperature
• Minimum start-up temperature
• Service voltage
• Chemical environment
• Maximum intermittent exposure temperature
• Electrical area classification

Once this information is known, most manufacturers will have wattage calculators where you can simply use the above data to calculate your requirements.

An Introduction to Thermocouples

Schematic of Type K Thermocouple
(courtesy of Wikipedia)

A thermocouple is a temperature sensor that produces a micro-voltage from a phenomena called the Seebeck Effect. In simple terms, when the junction of two different (dissimilar) metals varies in temperature from a second junction (called the reference junction), a voltage is produced. When the reference junction temperature is known and maintained, the voltage produced by the sensing junction can be measured and directly applied to the change in the sensing junctions' temperature.

Thermocouples are widely used for industrial and commercial temperate control because they are inexpensive, fairly accurate, have a fairly linear temperature-to-signal output curve, come in many “types” (different metal alloys) for many different temperature ranges, and are easily interchangeable. They require no external power to work and can be used in continuous temperature measurement applications from -185 Deg. Celsius (Type T) up to 1700 Deg. Celsius (Type B).

Thermocouple attachment unit

For pre-weld heat treatment, Type K thermocouples are generally used. Thermocouples can be directly attached to the workpiece by spot welding the junction of Type K thermocouple wire. The attachment is done with the help of a TAU, or thermocouple attachment devices. Thermocouples are attached so that there is firm contact between the sensing tip and the assembly being heat treated.