An
electric arc welder with a variable AC
voltage input of up to 600 VAC and a
rectifier to provide a DC link, a driven
high frequency boost stage with first and second leads connected to the DC link. The boost stage comprises an
inductor, a first series output
branch with a first primary winding connected to the first lead and a first
capacitor connected to the second lead, a second series output
branch with a second primary winding connected to the second lead and a second
capacitor connected to the first lead and a
high frequency operated switch between the leads and having an opened condition charging said capacitors by current through the primary windings in a first direction and discharging the
inductor and a closed condition charging the
inductor through the primary windings by current in a second direction and discharging the inductor to charge the capacitors. The switch is operated by a
power factor control circuit at a frequency greater than about 18 kHz. The boost stage has an AC output stage comprising the secondary winding network of a
transformer powered by current flow in the first and second primary windings. An output
rectifier converts said AC output to a first
DC voltage. At the final portion of the welder an output converter converts the first
DC voltage to a second
DC voltage connected across the arc of a
welding station and having a controlled weld current or
voltage.