What Is Welder Duty Cycle and Why Should You Care? - Kevin Caron

From www.kevincaron.com - Artist Kevin Caron explains what "duty cycle" means when talking about welders ....
Caron takes a break from working on his latest sculpture to compare the duty cycles of three different welders and explain what duty cycle is and why it's important. The first machine is the Longevity ProMTS 200, which has three welding functions in one machine: MIG, TIG and stick (or arc). He defines "duty cycle" as how long you can run a welder over a given period of time at maximum amperage. For instance, during a 10 minute period, the ProMTS's 30 percent duty cycle means you can weld for 3 to 3-1/2 minutes at 200 amps (its maximum amperage), and then the machine needs to cool down the rest of the 10 minute period. Caron says that this is true for each of the functions on the welder (MIG, TIG and stick. (That doesn't mean the machine will only run for 3 minutes at a time. It will weld for much longer than that, especially if you're not running at maximum amperage, but this example helps explain what duty cycle is and how it works.) For instance, Caron had just been welding at about 80 - 90 amps, so he estimates he could have welded continuously for an hour before the welder shut itself off to cool down. Next he shows Longevity's MigWeld 250P. It's a MIG welder with a pulse function. It also has a duty cycle of 30%, but he's welded at 150 to 170 amps on 1/2" plate with this welder and never had it shut down on him. Then he compares the MigWeld 250P to the Millermatic 251, which is another 200 amp MIG welder, although it doesn't have pulse. The Miller is also a transformer-based machine, whereas the Longevity is an inverter-based welder. The Millermatic's duty cycle is 60% at 200 amps and 40% at 250 amps, so they're pretty close as far as duty cycle. What determines duty cycle? Caron says a lot of it boils down to the size of the electronics, how durable they are, and how readily they shed heat. These welders have temperature sensors inside that determine whether the machine is getting overheated and needs to shut down to get back to a more manageable temperature. So the Millermatic is probably a little more robust. It probably has a heavier cooling fan, bigger cooling fins, more robust electronics, etc. Next Caron shows the AHP Alpha-TIG 200X, which is a TIG welder with a built-in stick welder. Its duty cycle at maximum amps is 60%. What's the difference? It has a big case, whereas the Longevity has three functions in a much smaller case. When Caron turns on the machine, he can feel the hot air coming out of the ducts 15 feet away. Why does duty cycle matter? It depends what you're going to do with the welder. Are you going to be doing short runs, like Caron does, or are you going to be in a production facility where the machine is running all day long? If you're going to be welding for a living, say, 6, 8 or 10 hours a day, you want the highest duty cycle you can find so you can keep working. See more how-to videos at www.kevincaron.com

[@dennisberg2474]

you are the most country knowledgeable dudes I have come across for welding. Definitely getting a follow today.

[@KevincaronSculpture]

Awesome thank you!

[@user-reddev77]

Duty cycles vary considerably by the exterior operating temperature. It's interesting how most manufacturers choose not to show the duty cycle rating in their specification data at 40C in accordance with EN60974-1. The reason for omitting the temperature data is to deliberately enhance the duty cycle figure to make the machine appear more durable to the buyer. For instance some machines rated at 35% duty cycle at 40C are capable of 100% or a full 10 minute cycle at a lower exterior temperature. It's not rocket science, the cooler the air being drawn in by the fan, the cooler it will keep the internal components and the welder will run for a longer period. If you are looking to make a smart purchase get a welder with a duty rated at 40C, with a 5 year warranty from a brand that doesn't use third-party service agents.

[@bgreenall01]

Kevin - if I could I’d shake your hand and thank you for your wisdom. Your videos have helped me a lot and I wish you all he best.

[@KevincaronSculpture]

You are very welcome

[@chris_758]

Hey Kevin. Thanx for this excellent video. I'm looking at taking up welding & there's a lot to learn & this was just my speed

[@KevincaronSculpture]

Glad I could help! It is a fun hobby that can turn into a full-time job before you know it. Welcome to the club and thank you for watching and posting.

[@w056007568]

Once again most useful and informative video, thanks. It also explains why my stick welder has oil in it (for cooling) and my son's doesn't. It has a noisy fan blowing!!

[@jacksonlee5189]

I just wanted to thank you Kevin for this video. I learned a lot and ended up getting a very nice Everlast welder with excellent duty cycle!

[@KevincaronSculpture]

Thanks for watching and have fun with the new welder!

[@KevincaronSculpture]

For sure a fan will help with the duty cycle. Had my evap. cooler running on high and got a much longer weld time out of the 30% machine. Great question!

[@Mercedessource]

thanks for taking the time to post this video

[@ScottandTera]

is the duty cycle based on a ten minute weld so a 60% means 6 min on and 4 min off?

[@KevincaronSculpture]

That is correct.

[@unclefrankonap1953]

another great video from the artman and his asst. thanks for answering this question.

[@KevincaronSculpture]

LOL, short story, I had a dodge ram with the 10 cylinder engine. Told the wife it had a high studleyness factor. Got the plate for Xmas. Finally got to faded for the police soi got a new plate. Great eyes! You are the first to ask.

[@garymurphy6361]

Thanks man my transmig rural pack 195 stopped working when iwelded a lot of welds.i thought i broke it. Fired it up after cooling down i left it for a week.was busy .she welded again .today .its old but a beuty

[@KevincaronSculpture]

Thanks for watching and posting. Happy to help.

[@phishertube]

Hey Kev, If I am running 30% and I just welded for 30mins should I leave the welder on so the fan cools it for 70mins or shut it off for 70mins before welding again. Basically what im asking is, whats better to cool off your machine, (a) leave machine on with fan running to cool off or (b) shut machine off and let it cool off? Thanks for all your incredible videos.

[@MusicMan6512]

Just wondering if the Duty Cycle would actually increase as the temp in your shop goes down??? I just thought maybe if would cool faster. Great video!!!!!

[@ReviewLife380]

Awesome information I didn't know about duty cycle. Awesome thanks

[@KevincaronSculpture]

Thanks for watching and posting!

[@Brad1237202]

Thanks Kevin! You cleared it up. I always wondered about duty cycle. Keep up the great videos! I'm learning all the time!

[@PeterAgostiniJdcap26]

great explanation Kevin. Do the digital welders tell how much weld time you have ? Like add up how many times you weld an clock down from there ? TU TY

[@wpoley]

Love your videos.Am new to tig.Bought the AHP 200 after watching your videos.Any where to get the basic settings for all the knobs to weld steel and then when you change to A/C for aluminum.Having trouble with so many settings.A chart or step by step for each knob would be nice.

[@robertharrison930]

Great video and explanation of duty cycle

[@KevincaronSculpture]

Thanks for watching!

[@GmGarlo]

if you have a good external fan, would that help any to keep the welder cool ?

[@KevincaronSculpture]

Yes it would help. Just make sure it is blowing in the right end of the machine.

[@jacquespoirier9071]

a very important side effect of the duty cycle is the arc stability, I ,ve bought a 250 AMP AC/DC arc welder that is designed for production use to the usage of a general maintenance dept , this welder weight about 1,000 lbs, tha arc stability is remarquable and you can weld any type of rod ( including 7018) without any difficulty, If I remember well, the duty cycle was 100% at full power

[@smitbar11]

I've got an old 1970's British made Oxford oil filled AC transformer machine, 230 or 415volts, amps up to 140A, you just can't overheat it, you can run at 140 amps all day long. They are still in business and UK made though no longer oil filled, more inverter and transformer based

[@KevincaronSculpture]

You have to love the old dogs! Long has it still runs and you are happy with it, Awesome!

[@Maher-]

Thanks for the video and the lady asking questions there , very enjoyable to watch and informative. I have a very small project and want to buy a stick welding machine, I want to buy a cheap welding machine like $50, Its 200A 60% ,What do you advice me? Thanks

[@KevincaronSculpture]

Thanks for watching!

[@KevincaronSculpture]

Stick is better outside or in tne wind. It is also better for really heavy steel , say over 1/2 inch. Pretty sure I talked about before.

[@billjue1753]

The problem is leaving the time a variable and undefined. For instance 1 month is only 8 percent of a year. If you pick 10 minutes to calculate your duty cycle is that the standard for the industry?

[@KevincaronSculpture]

Yes, 10 minutes is normally the standard for figuring out duty cycle.

[@blacknote3070]

Hi .. what exactly does it mean you need to cool it of for a while after hitting the duty cycle.....Do you really need to shutdown the machine? Or the machine was in standby mode (power On)and do nothing for a while

[@KevincaronSculpture]

When the machine reaches the duty cycle it will stop welding. The fans will stay on and the machine is still running but no welding until it cools itself down. You can just let it run and take a break or shut it off and take a break. If you keep the insides clean of dust it also helps it run cooler and longer.

[@johnkemnitz7478]

when you say rest does that mean stop welding or turn the machine off?

[@KevincaronSculpture]

stop welding for sure, If you can turn the machine off it will cool off that much faster.

[@rijwansaifi4439]

Good explanation.

[@KevincaronSculpture]

Thanks for posting. Don't forget to click and ad or 2 if you get the chance. Helps pay for the videos.

[@johnmacneill6403]

thanks for your help

[@KevincaronSculpture]

No worries!

[@VisorBlue]

Helpful video, as usual. Let's say you're working on one of your amazing pieces, a large one with a 6-foot seam you're closing with Mig, I assume you're not usually maxing the amperage right? I, also, assume that you aren't going to do that full 6' seam in one long continuous weld. So, that would mean you aren't coming anywhere near the welder's duty cycle, right? How thick of a piece of steel would you be welding at max power?

[@VisorBlue]

***** I can hear your creative juices gurgling from here. What large pieces are you planning to make with 1/2" steel to tax the duty cycles? :-)

[@VisorBlue]

***** I like that piece (as well as ALL your others). Yeah, I know. Soon!

[@shadow7423]

Thanks Kevin for this video!

[@CharlesStruble]

Thanks guys. So, I'm thinkin' oxy acetylene has 100% duty cycle, huh? Also, would it affect duty cycle if ya put a fan blowing into the air grills on the machine?

[@johnvgig]

You’d have to be careful trying that. You’d have to ensure you had the additional air movement be in the SAME direction as the machine’s airflow.

[@tnsturner]

I read on the internet that a person with a defibrillator can weld using a welder under 160 amp do you know anything about this

[@KevincaronSculpture]

Sounds like bs to me but I really have no idea.

[@justinhughes5663]

I'm still lost lol. On my everlast 200st 35%@120amps (110v)...what does that mean

[@KevincaronSculpture]

Duty cycle, means you can weld for about 3.5 minutes out of 10 if you are running on 110 volt.

[@justinhughes5663]

Kevin Caron, Artist what about 100%@70 amps (110v) and also 60%@90amps (110v)?

[@WARZONEBOXINGCLUB]

Thank you sir

[@KevincaronSculpture]

Welcome

[@top5bigdog]

Hey Kevin, just got my Alphatig 200xwondered what size breaker is needed to run this unit? My 10 amp breaker kicks out

[@KevincaronSculpture]

Wants a 30 amp, Runs on the 20 I have just fine.... Have never maxed it out on 110 though..

[@nathanmontgomery734]

this was extremely helpful thank you

[@KirkOfBellevue]

is there a number for how long it will run at a given setting?

[@KevincaronSculpture]

Every machine is different but they run between about 25 % to 65 % at max output..

[@countrylogic9168]

So if I have a 135 amp mig welder the lower the amp the more time I can run it....right

[@KevincaronSculpture]

+Country logic All depends on the duty cycle for "that" machine. It's all about heat. If you can get rid of the heat quickly you can run longer..

[@top5bigdog]

Does it make a difference if it's a GFI 20A?

[@KevincaronSculpture]

Not that I am aware of...

[@MrObsvenchilde]

So could I just water cool my welder for a better duty cycle?

[@KevincaronSculpture]

True, if you had a way to pull heat out of the machine better, you would have a longer duty cycle.

[@Justicejamesb]

Would you recommend a good beginner welder? I'm wanting to weld thin sheet metal on cars, and general repairs around the house. I was looking at the Longevity 140, but I wanted an expert opinion...

[@ScottandTera]

tnx for the reply

[@top5bigdog]

I guess it's good because I tried another receptacle and it worked

[@fixt100]

Yet another great vid say hi to "The Voice" for me :)

[@outdoorflowsports]

and whats the Duty Ratio %?

[@MrYasmanileyva]

Ur a life saver

[@amacca995]

Worth mentioning if you turn off your welder while its on duty cycle it will take longer to cool down given heat is the core reason for the overheat/dutycycle. Actually i would recommend never turning it off while on duty cycle. And lets face it most of us have had to wait for that damn thing!

[@KevincaronSculpture]

So True!

[@KevincaronSculpture]

My duty is 80 proof!

[@ChiNguyen-wf1qt]

Just wonder are you professional welder own your own welding business? Or just made these video to help people understand and learn welding

[@KevincaronSculpture]

I am an artist, I use welders to make my sculptures. I also enjoy sharing what I learn with you guys. You can find my work at www.kevincaron.com

[@HEADBANGRR]

Having an issue with a flux core welder. It turns off every 5 to 10 seconds

[@KevincaronSculpture]

Bummer, tell us more.

[@HEADBANGRR]

@@KevincaronSculpture took care of it already. It was the outlet I was plugging into was bad

[@JonathanLov]

You look like Cary Grant.

[@KevincaronSculpture]

Thank you!

[@NotSoCrazyNinja]

Why don't manufacturers just make welders that can handle constant welding without any chance of overheating? Yeah I know, it will increase the price, but with the right designs, it shouldn't be much of a price increase.

[@KevincaronSculpture]

Everlast has some welders that run in the 60% duty cycle. if you want 100 % at max amps you will need to pony up about $4k for a 250 amp machine.

[@KevincaronSculpture]

Awesome!

[@Wetstriker]

I run my 30% DC welder for 3 hours, then leave it off for 7 hours.

[@gavowassy7655]

Looks like Terry wogan

[@KevincaronSculpture]

Thanks I think!

[@dowillwill]

Kevin with all due respect, I love your channel I love the information that you give out to all of us but we've never seen your wife and just like a radio station that you never see the disc jockey but you always hear their voice sometimes you visualize what they look like. wife's voice reminds me of Roseanne. lol

[@KevincaronSculpture]

+will rojas Look over here,,, www.kevincaron.com/video_detail.php?id=331 That's the "Voice",,

[@dowillwill]

+Kevin Caron, Artist Rock on you guys are the "greatest".

[@osbaldohernandez9174]

Basically just give your machine a break everytime

[@KevincaronSculpture]

We take breaks together!

[@Poverty_Welder]

I still don't get it, I'm probably regarded and should just give up my dreams

[@FrustratedBaboon]

The doody cycle of a welder is when it takes a crap once in a while.

[@Poverty_Welder]

I still don't get it, I'm probably regarded and should just give up my dreams