Converting 90 amp AC welder to DC - Page 5
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  1. #101
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    Re: Converting 90 amp AC welder to DC

    I didn't know that these welders have aluminum windings.Do the 131's,151's and 171's have aluminum windings?I'm scared to bend on the aluminum wire to much because it just might break off.
    I made a couple of aluminum brackets to mount the rectifier with,I mounted it to a piece of wood so as to check some clearance issues.I will have to bend and finish these brackets after I get the rectifier so I will have something to go by.
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  2. #102
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    Re: Converting 90 amp AC welder to DC

    I had some thoughts about this....

    Perhaps you could just leave the alum wire in place as much as possible, and just route copper to and from where the alum is.

    The 151 has an inductor and people are adding a capacitor before the inductor. The 90a does not have an inductor, so there will not be much but the copper resistance to limit the current spike when the wire contacts the work. I will be very interested to see what your results are

    Make sure to connect the motor drive wires to the transformer output before the rectifier you add; the board needs AC and will not work on DC.

    That three phase rectifier block you posted is, I believe, used on the inputs at 240v and 50A or so.
    "Great spirits have always encountered violent oppostion from mediocre minds." -- Albert Einstein

  3. #103
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    Re: Converting 90 amp AC welder to DC

    I got the cap mounted,temporarily,I'll have to take it back out to do other things then put it back in.I just cut a strip out of some thin aluminum and made a bracket.
    That aluminum wire is so stiff and brittle I'm not going to bend on it too much.I'm going to try and leave it where it is and just go with the 8 AWG wire from there.It would be h.ll if it broke off up in the windings somewhere.My nephew borrowed my good camera today to take to a cook-out so the pics might be a little blurry.
    Don't some welders have a thyristor mounted on the rectifier to cancel out any spikes that may come back to the rectifier?Like I say,I don't know much about this stuff but I am pretty good mechanically with nuts and bolts.
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    Last edited by dugndeep; 05-28-2011 at 05:58 PM.
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  4. #104
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    Re: Converting 90 amp AC welder to DC

    The 151 seems to have aluminum windings,I would guess they all do.
    Most of the welders have a varistor (MOV)across the rectifier,usually a 60-90v one.
    Your rectifier is pretty high voltage,one of these would work.:http://www.radioshack.com/product/in...ductId=2062574

  5. #105
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    Re: Converting 90 amp AC welder to DC

    I was talking about the output side of the rectifier,say as where you start the arc or stop the arc,surge coming back to the rectifier,how would you hook it up,across both wires or just inline on one wire?Like I said ,I'm not electronically inclined.I read somewhere that you should put one on both sides of rectifier,incoming and out going.
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  6. #106
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    Re: Converting 90 amp AC welder to DC

    Got my good camera back,before I said I made the strap out of aluminum,I got aluminum and cooling on the brain,it's made out of tin.A couple of better pics,not blurry.
    I might have to stick that other little AC fan back in there somewhere,or at least take that cover plate that I put there under the cap back off to open up the other fan holes that I drilled into the bottom of the case.
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    Last edited by dugndeep; 05-29-2011 at 10:54 AM.
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  7. #107
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    Re: Converting 90 amp AC welder to DC

    The MOV goes between the Plus and Minus of the output rectifier.:http://weldingweb.com/attachment.php...1&d=1235527368

  8. #108
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    Re: Converting 90 amp AC welder to DC

    Would the MOV across the output of your rectifier change anything such as output values?Wonder what the values are of that Radio Shack MOV?It doesn't give no info about it on the webpage.
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  9. #109
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    Re: Converting 90 amp AC welder to DC

    Quote Originally Posted by dugndeep View Post
    Wonder what the values are of that Radio Shack MOV?It doesn't give no info about it on the webpage.
    From the product summary...

    "use to replace "blown" V130LA20A MOVs in surge protectors."

    V130 means 130 volt clamping. 20A is the current rating.

    That Radio Shack part is for line voltage surge protection.

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  10. #110
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    Re: Converting 90 amp AC welder to DC

    The MOV won't have an effect on the output.
    The voltage rating on the rectifiers you are installing are very high,so the odds of a damaging voltage spike are small.
    The MOV will nullify voltage spikes at 130-180v depending on how it is used.

  11. #111
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    Re: Converting 90 amp AC welder to DC

    I went to Digi-key to check them out,didn't know what kind of value I should be looking for.The Radio Shack comment was "he used this one to replace a V130LA20A MOV in a surge protector".Still don't tell me what the value of this one is.
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  12. #112
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    Re: Converting 90 amp AC welder to DC

    The voltage rating on the rectifiers you are installing are very high,so the odds of a damaging voltage spike are small

    So I wouldn't really need one at all then.
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  13. #113
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    Re: Converting 90 amp AC welder to DC

    It would probably be ok.

  14. #114
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    Re: Converting 90 amp AC welder to DC

    I just hope the rectifier is of good quality, for $10.77 + free shipping you can't complain I reckon.At today's exchange rate,$1 US equals 6.50 Chinese Yuan so that comes to 71.50 Chinese.That is about what you would give for one here in the US with US dollars.
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  15. #115
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    Re: Converting 90 amp AC welder to DC

    I don't know what to do about connecting the aluminum transformer wire to the 8 AWG wire I got.I don't like those mechanical connectors I got at Lowes.Their just big and gawky.It was originally crimped from the factory with some sleeve crimp connectors,their not steel but I don't think their aluminum either.They won't stick to a magnet.I got a regular old hand crimper,I don't have any luck crimping wires,usually the ends pull off or some kind of bull crap,or the wire breaks off at the connector.I would like to have this crimper from Harbor Freight,it is on sale for $49.99.It's a hydraulic crimper with a bunch of different dies.I tried to use a 20% off coupon online last nite and it wouldn't let me.It would have just been $39.99 if it would have worked.This crimper would just be handy to have.I'll have to look around for some crimp sleeves.Aluminum would probably be easier to get a good crimp on.I'll just have to look around and see what I can find.I just wonder if it would be alright if the wires touch,they come from the factory touching plus they didn't have any aluminum wire compound on them either.I got some so I will be putting it on there.
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  16. #116
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    Re: Converting 90 amp AC welder to DC

    Well I went and splurged and bought the hydraulic crimper.I went just to get the racheting crimper for $12,had it in my hand and the boy at the counter said that the hydraulic one was on sale for $49.I said well since it's on sale you probably wouldn't let me use a 20% coupon too,he said sure,as long as the coupon is valid,which it was.So for $42 I got a hydraulic crimper,I ain't tried it yet,hope it works.I've seen others just like it on ebay for well over $100,so hopefully I've saved a little by going to Harbor Freight.I had a coupon for a free pair of all-purpose scissors with a purchase so I got them too.
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  17. #117
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    Re: Converting 90 amp AC welder to DC

    Here's what I got in the mail today from Hong Kong in a plain white paper envelope with 2 of the tabs sticking out the side of the envelope and a third tab bent.Other than the bent tab,the rest of it seems alright.I'm surprised it made it here in the shape it is in.I reckon that is what you get with free shipping.Must have a shortage of small cardboard boxes lol
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  18. #118
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    Re: Converting 90 amp AC welder to DC

    Now I will have to figure out how to check it to make sure it works.I still haven't got my 8 awg ring connectors yet.Should be here any day.
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    Last edited by dugndeep; 06-06-2011 at 03:06 PM.
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  19. #119
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    Re: Converting 90 amp AC welder to DC

    I got the rectifier mounted,I got about a 16th of an inch in front of the fan & the transformer plus I removed the slats in the back in front of the fan.You won't believe how much more air you will have without this.I ordered a finger Guard from Digi-key for $1.62 to protect the fan.
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  20. #120
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    Re: Converting 90 amp AC welder to DC

    Here's the rectifier with it's bracket ready to be mounted.I left the bracket long to help aid in cooling.
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  21. #121
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    Re: Converting 90 amp AC welder to DC

    Here's the capacitor wired up and ready to go.I also added rivet nuts on the wire reel holder instead of the self-tapping sheet metal screws that originally came from the factory with.I was planning on doing this anyway but I had to now because the self tappers were going to touch the DC out terminals of the rectifier.
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    Last edited by dugndeep; 06-08-2011 at 08:31 AM.
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  22. #122
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    Re: Converting 90 amp AC welder to DC

    I reckon I got everything where it needs to be,now I just need to get some 8 AWG connectors and get it wired up.
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  23. #123
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    Re: Converting 90 amp AC welder to DC

    I got my 8 awg connectors in the mail today.Finally got it all wired up.Plugged it in and turned it on,and it works.Nothing popped or blew up so that was good.Haven't tried to weld anything with it yet but I did check it with a volt meter.
    On low it puts out 34.23 volts DC and on high it puts out 40.36 volts DC.
    Now just have to try to weld with it and see what happens.Hopefully it will be alright,just have to keep an eye on it for awhile.
    Thanks to Bluewelders and the others for all the help and support,couldn't have done it with out ya'll............Doug
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    Last edited by dugndeep; 06-08-2011 at 06:23 PM.
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    Chicago Electric 90 amp DC flux-core
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  24. #124
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    Re: Converting 90 amp AC welder to DC

    Another few pics.I was going to try and solder everything but that hydraulic crimper is sweet and does a real good job that I only soldered the final connections to the gun and the ground clamp.It is a true DC flux core welder now.
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    Last edited by dugndeep; 06-08-2011 at 06:26 PM.
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  25. #125
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    Re: Converting 90 amp AC welder to DC

    I'd be interested to see a few welds with it. I've been following this thread with interest.
    My cheapie little C/H flux core is a DC output flux-core welder, but it doesn't have a cap. Seems to weld okay though, considering the skill of the operator,
    Campbell Hausfeld 80 Flux Core.
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