Converting 90 amp AC welder to DC - Page 3
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  1. #51
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    Re: Converting 90 amp AC welder to DC

    The flattened copper tubing and solder,should give a good connection.
    On the aluminum wire they seem to use just a type of crimp type connector or nuts and bolts,maybe with some anti-oxide paste.
    Terminal strips tend to not work for high amperage,.they heat and work loose.
    I use one of these when I can,on copper tubing ,with solder.
    http://www.radioshack.com/product/in...uctId=2062636#

  2. #52
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    Re: Converting 90 amp AC welder to DC

    I found this in a box of whatever electronic parts,don't know no more about it than what is written on it.I'm trying to keep this conversion as cheap as possible by using what I have on hand.
    You would not believe what a 3-port wire terminal cost,too much for my blood so I reckon I will be using the copper pipe to make my connections.
    Would a 40 volt capacitor work?They have a 47,000uf 40 volt cap,actually it's $2 dollars higher than the 50 volt but they have more than 2 in stock.Plus it has a higher ripple current value.Almost double what the 50 volt cap has.
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  3. #53
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    Re: Converting 90 amp AC welder to DC

    You could use a couple of these in parallel for a resistor.:http://www.radioshack.com/product/in...ower+resistors

  4. #54
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    Re: Converting 90 amp AC welder to DC

    That's probably what I'll do for resistors,just go to Radio shack.Thanks for the find.I'm thinking about ordering the cap tomorrow.I'm going to take a chance and order the 47,000 50V and hope it's still in stock,if not I'll go with the 39,000 50V.They have a 58,000 50V in stock,which is the one I would really like to get,only drawback,$62 dollars.
    Maxus Pro-125 Mig
    Chicago Electric 90 amp DC flux-core
    Lincoln Electric AC 225 tombstone
    O/A torch
    M/O mini-torch
    10 acres of flatland
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  5. #55
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    Re: Converting 90 amp AC welder to DC

    There must be someone reading this who has done it already. Did it weld better?

  6. #56
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    Re: Converting 90 amp AC welder to DC

    I've wondered that myself.I think everybody thinks it's not worth the time or money.
    I think the manufacturer's of these welder's keep an eye on these forums,they seen where everybody was putting caps in their Harbor Freight 131's,151's and 171's.Woodymayne bought a 131 off ebay here recently and it already had the cap in it.Maybe if my conversion works they will take notice and change these welders over to DC,I know they could do it for a whole lot cheaper than I can.
    Maxus Pro-125 Mig
    Chicago Electric 90 amp DC flux-core
    Lincoln Electric AC 225 tombstone
    O/A torch
    M/O mini-torch
    10 acres of flatland
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  7. #57
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    Re: Converting 90 amp AC welder to DC

    I ordered my capacitor today,just hope it's in stock when they get it so I can get the one I want.Went by Radio shack and picked up a couple of 100 ohm 10 watt resistors and some thermal heat compound for putting on the screws of the capacitor when I make my connections.I was checking out the schematics to the Lincoln Electric Power Mig 140 and it said to use thermal heatsink compound on all bolted aluminum connections such as the capacitor when reattaching,so that's what I will do.
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    Maxus Pro-125 Mig
    Chicago Electric 90 amp DC flux-core
    Lincoln Electric AC 225 tombstone
    O/A torch
    M/O mini-torch
    10 acres of flatland
    15 acres of holler

  8. #58
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    Re: Converting 90 amp AC welder to DC

    You don't want to put that compound on the capacitor connections. It's for things like transistor mounting tabs and rectifier mounting studs where they attach to a 'heat sink'. It improves heat transfer, but does nothing to help electrical conductivity. For that, you need the stuff I bought called, Cool Amp. You apply it to copper and a chemical reaction occurs that leaves a thin sliver plating on the copper which DOES improve electrical energy transfer.

    Papa
    Lincoln Idealarc 250 (circa 1962)
    Lincoln Weldpak 155 w/Mig Kit
    Lincoln Squarewave TIG 175

  9. #59
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    Re: Converting 90 amp AC welder to DC

    Actually bought that to put in between a computer processor and it's heatsink.Lincoln recommends Dow 340 thermal heatsink compound, it's about $30 dollars for a tube of that size.I figured it was sorta about the same thing except this doesn't have silver in it.This is the same stuff as the dow thermal heatsink compound,even has the same stuff in it,this is just the cheap stuff.I'll check into it further just to be sure.
    Last edited by dugndeep; 05-18-2011 at 06:15 PM.
    Maxus Pro-125 Mig
    Chicago Electric 90 amp DC flux-core
    Lincoln Electric AC 225 tombstone
    O/A torch
    M/O mini-torch
    10 acres of flatland
    15 acres of holler

  10. #60
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    Re: Converting 90 amp AC welder to DC

    Here's what they each got in them.
    Radio Shack thermal compound:
    Polydimethylsiloxane
    Zinc Oxide
    Polytetrafluoroethylene
    Fumed Silica

    Dow 340 thermal compound:
    Zinc Oxide
    Polydimethylsiloxane
    Grease-like Silicone Fluid
    Dow web site said this stuff can be used on heatsinks or electrical bolted connections.Especially aluminum connections like on a capacitor.I figured the Dow 340 would have silver in it but it doesn't.
    Maxus Pro-125 Mig
    Chicago Electric 90 amp DC flux-core
    Lincoln Electric AC 225 tombstone
    O/A torch
    M/O mini-torch
    10 acres of flatland
    15 acres of holler

  11. #61
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    Re: Converting 90 amp AC welder to DC

    I got my resistor connectors soldered on,here's a few pics,everybody likes pictures lol That capacitor has 10-32 screws with it so I used 2 ring connectors that fit that thread size.Should mount right on top of the capacitor with no problems.Wonder which is more accurate,the Fluke or the Innova?
    Attached Images Attached Images     
    Last edited by dugndeep; 05-18-2011 at 06:45 PM.
    Maxus Pro-125 Mig
    Chicago Electric 90 amp DC flux-core
    Lincoln Electric AC 225 tombstone
    O/A torch
    M/O mini-torch
    10 acres of flatland
    15 acres of holler

  12. #62
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    Re: Converting 90 amp AC welder to DC

    I ain't trying to prove nobody wrong,I just don't want people to think that I am making this stuff up.This is the schematic for the Lincoln Electric Pro mig 140.They recommend putting Dow 340 Thermal Heat Sink Compound on the aluminum connection of the capacitor when reattaching.
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    Maxus Pro-125 Mig
    Chicago Electric 90 amp DC flux-core
    Lincoln Electric AC 225 tombstone
    O/A torch
    M/O mini-torch
    10 acres of flatland
    15 acres of holler

  13. #63
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    Re: Converting 90 amp AC welder to DC

    That's interesting. I don't think I've ever come across heat sink compound being used in that manner in my many years as an equipment tech.

    Hope it all works well when you get it done. Keep us posted.
    Lincoln Idealarc 250 (circa 1962)
    Lincoln Weldpak 155 w/Mig Kit
    Lincoln Squarewave TIG 175

  14. #64
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    Re: Converting 90 amp AC welder to DC

    When I connect aluminum to aluminum I use Burndy P8A Anti-Oxidant Electrical Joint Compound.
    Also very good for coating the aluminum feed wires in your breaker box.
    Also has several other uses.
    http://www.galco.com/scripts/cgiip.e...ly=0&tabid=ovr

  15. #65
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    Re: Converting 90 amp AC welder to DC

    Should keep it all in the family and use a $2.00 HF meter . FYI 5 CWI 's and our Lincoln Electric service center said it is BS to do SSFCAW with AC , it should not work and is crap !!!! Will try myself this weekend . John

  16. #66
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    Re: Converting 90 amp AC welder to DC

    Quote Originally Posted by ltvtom View Post
    When I connect aluminum to aluminum I use Burndy P8A Anti-Oxidant Electrical Joint Compound.
    Also very good for coating the aluminum feed wires in your breaker box.
    Also has several other uses.
    http://www.galco.com/scripts/cgiip.e...ly=0&tabid=ovr

    Dow Corning makes similiar stuff-Dow Corning 4 Electrical Connection Compound

    I don't know why they use the 340 stuff instead of the 4 on the cap connections.I just figure it is about keeping the heat out of the aluminum connection.I figure they know more about it than I do.

    I got one of those too,free with a coupon out of the Sunday paper.
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    Last edited by dugndeep; 05-19-2011 at 08:58 AM.
    Maxus Pro-125 Mig
    Chicago Electric 90 amp DC flux-core
    Lincoln Electric AC 225 tombstone
    O/A torch
    M/O mini-torch
    10 acres of flatland
    15 acres of holler

  17. #67
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    Re: Converting 90 amp AC welder to DC

    I suppose heatsink compound would keep the joint from oxidizing further and remove hot spots,but I have never seen it used that way.
    Shouldn't hurt anything,whatever the theory behind it.

  18. #68
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    Re: Converting 90 amp AC welder to DC

    Quote Originally Posted by Bluewelders View Post
    I suppose heatsink compound would keep the joint from oxidizing further and remove hot spots,but I have never seen it used that way.
    Shouldn't hurt anything,whatever the theory behind it.
    That's what I figured too,my nephew needed it for his computer so I told him to leave me a little for that purpose.
    Maxus Pro-125 Mig
    Chicago Electric 90 amp DC flux-core
    Lincoln Electric AC 225 tombstone
    O/A torch
    M/O mini-torch
    10 acres of flatland
    15 acres of holler

  19. #69
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    Re: Converting 90 amp AC welder to DC

    To DM the HF tester is good , tried against $ 500 .00 fluke read the same !!! Now stick it on the output af the HF 90 and show AC or DC ????? John

  20. #70
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    Re: Converting 90 amp AC welder to DC

    Go to HF website look up SKU 98871 open up owners manuel PG -8 tell me what you find ???? John

  21. #71
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    Re: Converting 90 amp AC welder to DC

    It is just AC,I measured it,on low-26.2 ac volts,on high 31.3 ac volts.
    The manual says it's dcen but it's not.It says ac output on the front like papaharley said.

    It's still AC.
    Maxus Pro-125 Mig
    Chicago Electric 90 amp DC flux-core
    Lincoln Electric AC 225 tombstone
    O/A torch
    M/O mini-torch
    10 acres of flatland
    15 acres of holler

  22. #72
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    Re: Converting 90 amp AC welder to DC

    Would a 100,000uf 50V cap be too much capacitance?Also wondering if a 40 Volt would work?Probably going to get an e-mail today saying they are sold out of the one I ordered.That's why I'm wondering about the 100,000uf, $7 more and I can get it.
    Last edited by dugndeep; 05-20-2011 at 08:35 AM.
    Maxus Pro-125 Mig
    Chicago Electric 90 amp DC flux-core
    Lincoln Electric AC 225 tombstone
    O/A torch
    M/O mini-torch
    10 acres of flatland
    15 acres of holler

  23. #73
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    Re: Converting 90 amp AC welder to DC

    A larger capacitor shouldn't hurt anything,though physically it is a pretty big can.
    You could sell it for about what you have in it ,if it was not what you wanted.
    40v on a live torch is pretty low.

  24. #74
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    Re: Converting 90 amp AC welder to DC

    I could probably get it in there somewhere,it is 3" diameter X 4 1/8" tall.So the 40V is out of the question.Just have to wait and see I reckon.
    I did pick up some 10 gauge wire today,that 8 gauge wire is pretty stiff and hard to maneuver where you want it to go plus finding 8 gauge connectors is turning out to be harder than I thought.The bridge rectifier has spade terminals on it but I can't find any spade connectors for 8 gauge wire.I've just looked locally but could probably go to Lexington to an Electronics store and find them.That 10 gauge wire looks pretty skimpy compared to the 8 gauge wire when you put them side-by-side.I would like to use the 8 gauge wherever possible.
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    Last edited by dugndeep; 05-20-2011 at 02:54 PM.
    Maxus Pro-125 Mig
    Chicago Electric 90 amp DC flux-core
    Lincoln Electric AC 225 tombstone
    O/A torch
    M/O mini-torch
    10 acres of flatland
    15 acres of holler

  25. #75
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    Re: Converting 90 amp AC welder to DC

    For the capacitor wiring,10ga is plenty.
    The duty cycle is low enough that super large wire is not necessary.

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