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I've had this bookmarked forever,just refound it...LOLhttp://www.blinkenbyte.org/welder_co...onversion.htmlIf I had the know-how I would try it....LOLLast edited by dugndeep; 05-03-2011 at 12:40 PM.Maxus Pro-125 MigChicago Electric 90 amp DC flux-coreLincoln Electric AC 225 tombstoneO/A torchM/O mini-torch10 acres of flatland15 acres of holler
Reply:
Originally Posted by dugndeep
I've had this bookmarked forever,just refound it...LOLhttp://www.blinkenbyte.org/welder_co...onversion.html
Reply:I was wondering about the fan also but that welder didn't come with a fan,the fan in my welder is 120 volt and hooks up to the switch via a piggy back connector.I reckon he didn't think about using a 120 volt fan and hooking it up to the switch.Maxus Pro-125 MigChicago Electric 90 amp DC flux-coreLincoln Electric AC 225 tombstoneO/A torchM/O mini-torch10 acres of flatland15 acres of holler
Reply:This is wrong all mig welders are DC only never AC . The only AC that works is submerged arc AC . John
Reply:Have you downloaded and read HF's manuals for these 90 amp wire welders? There aren't any diodes in the wiring diagram or parts list.
Reply:
Originally Posted by Pavinsteelman
This is wrong all mig welders are DC only never AC . The only AC that works is submerged arc AC . John
Reply:I wish it was a little more detailed and had some specs on the electronics he used, say could you just use 1 capacitor,you don't even need the fan circuitry because it's already there.If I had the electronics just laying around or could get them for little, if nothing,I would try it.These welders are a dime a dozen it seems anymore,you see them everywhere.I would just like to see and feel the difference in the weld capability.Could you just use a 2 phase bridge rectifier?I know nothing about this stuff but it still interest me.Last edited by dugndeep; 05-05-2011 at 07:06 PM.Maxus Pro-125 MigChicago Electric 90 amp DC flux-coreLincoln Electric AC 225 tombstoneO/A torchM/O mini-torch10 acres of flatland15 acres of holler
Reply:I'm confused and upset by this guy's website. I must agree with Pavinsteelman! His welder already was DC! I'm convinced he doesn't quite have a full grasp of what he is talking about or how electricity works... He basically just did the same mod we all do here, add capacitors & a resistor. Then he isolated the other DC components in the unit to a separate transformer. This is exactly what I did with my custom setup:http://weldingweb.com/vbb/showthread.php?t=43110He did a nice job and all, don't get me wrong. Just his explanation is wrong.Chicago Electric 131 Dual MIG Welder 120Vhttp://www.gr8lakeinnovations.com2x Associates of Automotive Technology: Transmission Technician & Under Car TechnicianAssociates of Electrical Engineering Technology
Reply:
Originally Posted by sirhannick
I'm confused and upset by this guy's website. I must agree with Pavinsteelman! His welder already was DC! I'm convinced he doesn't quite have a full grasp of what he is talking about or how electricity works... He basically just did the same mod we all do here, add capacitors & a resistor. Then he isolated the other DC components in the unit to a separate transformer. This is exactly what I did with my custom setup:http://weldingweb.com/vbb/showthread.php?t=43110He did a nice job and all, don't get me wrong. Just his explanation is wrong.
Reply:That's messed up. There should be some kind of law against calling it a MIG welder...Chicago Electric 131 Dual MIG Welder 120Vhttp://www.gr8lakeinnovations.com2x Associates of Automotive Technology: Transmission Technician & Under Car TechnicianAssociates of Electrical Engineering Technology
Reply:Could 4- 25 amp 50 volt bridge rectifiers be put together parallel & work to get 100amps 200 volts or will it just not work like that,as I said before,I know nothing.........they are just $3.49 a piece at radio shackHere's a pic of a 100 amp 1200volt on ebay for $8
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Last edited by dugndeep; 05-06-2011 at 09:46 AM.Maxus Pro-125 MigChicago Electric 90 amp DC flux-coreLincoln Electric AC 225 tombstoneO/A torchM/O mini-torch10 acres of flatland15 acres of holler
Reply:I'm just trying to figure out how he has it hooked up.On my welder the ground clamp is hooked straight to the wire that he has a black wire on.Did he switch polarity?My ground is hooked to the wire with the arrow.I wish he had drawed it out in detail to show which wire goes where,which wire hooks to gun,etcGun lead hooked up here.He has positive white wire hooked to gun lead
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Last edited by dugndeep; 05-06-2011 at 10:20 AM.Maxus Pro-125 MigChicago Electric 90 amp DC flux-coreLincoln Electric AC 225 tombstoneO/A torchM/O mini-torch10 acres of flatland15 acres of holler
Reply:Yes you can parallel the devices to increase the current handling capability. This is done all the time with tubes and transistors in power amplifiers. I think the 8 dollar ebay device might work better for you as it will be less wiring to mess with.Lincoln Idealarc 250 (circa 1962)Lincoln Weldpak 155 w/Mig KitLincoln Squarewave TIG 175
Reply:2 - 20,000 uf electrolytic 50 volt capacitors on ebay=$5+$3.99 shipping1 -bridge rectifier on ebay=$8+ free shippingresistor-$2 at radio shack10 gauge wire-.25 cents a footSo for under $25 you could turn your HF 90 amp AC welder into a 90 amp DC welderMaxus Pro-125 MigChicago Electric 90 amp DC flux-coreLincoln Electric AC 225 tombstoneO/A torchM/O mini-torch10 acres of flatland15 acres of holler
Reply:No way is this AC mig it will not work ,some one grab a meter and check it out ???? You need polaarity control for fine wire and selfshielded work or it comes out like crap . John ps the exception is submerged arc ac/dcep/dcen it all workes to a procedure . John
Reply:
Originally Posted by Pavinsteelman
No way is this AC mig
Reply:The HF 90 Amp Flux Wire Welder --------------------------------------------------------------------------------I had posted this comment before but it's worth repeating for people whonever had the opportunity to open up and exam the HF 90 Amp Flux Wire Welder .This was my experience:FYII bought a used one off craigs list a while back that needed repair.I was shocked to see it was an ac only machine. No rectifiers at all,pure ac off the transformer.If you download the manual they say the output is DCEN which would mean "direct current electrode negative".After I repaired the wire feed (had a blown SCR) I tested it out. It did weld,but compared to my Lincoln it was mediocre at best. You could weld two pieces of steel, but with a lot of splatter.I put it back on craigs list and resold it.Tom
Reply:
Originally Posted by Pavinsteelman
No way is this AC mig it will not work ,some one grab a meter and check it out ???? You need polaarity control for fine wire and selfshielded work or it comes out like crap . John ps the exception is submerged arc ac/dcep/dcen it all workes to a procedure . John
Reply:Ok guys im going to test it , takin a roll of ESAB coreshied 8 , stickit in my Linde feeder and run it in my AC - TM -500 see if it works ?????? John
Reply:let me know. I'll take the side off and take a pic of it just to show ya there aint nothin in there cept a transformer and the leads hooked directly to it
Reply:Page 22.:http://images.harborfreight.com/manu...4999/44567.PDF
Reply: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.Last edited by dugndeep; 05-07-2011 at 12:17 PM.Maxus Pro-125 MigChicago Electric 90 amp DC flux-coreLincoln Electric AC 225 tombstoneO/A torchM/O mini-torch10 acres of flatland15 acres of holler
Reply:Just looked at the owners manual on line [ OUTPUT DCEN } what more can you want talked to 3 CWI 's at work all said no AC MIG !!! JOHN
Reply:After reading the owner's manual posted above, it is VERY EASY to see that this is most definitely an AC output welder.Say what you want about my cheap Campbell Hausfeld welder, but at least it's output is DC!...
Last edited by Jimbob; 05-09-2011 at 10:14 PM.Campbell Hausfeld 80 Flux Core.Mastercraft AC-230 Buzz box.
Reply:Yep,it's AC alright.I know now that the AC coming off the transformer has no polarity so it does not matter which wire goes to your AC in on your bridge rectifier.You just have to be sure that your DC + coming off of bridge rectifier goes to your ground clamp and your DC- coming off of bridge rectifier goes to your gun.I thought he had reversed the polarity but that was before I knew that the AC coming from transformer has no polarity.
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Last edited by dugndeep; 05-09-2011 at 10:36 PM.Maxus Pro-125 MigChicago Electric 90 amp DC flux-coreLincoln Electric AC 225 tombstoneO/A torchM/O mini-torch10 acres of flatland15 acres of holler
Originally Posted by Pavinsteelman
Just looked at the owners manual on line [ OUTPUT DCEN } what more can you want talked to 3 CWI 's at work all said no AC MIG !!! JOHN
Reply:I'm trying to figure how much resistance I would need for a 59,000uf 40 volt capacitor.I've been reading up on this stuff and have the formula,just wondering whether to go with 2 smaller caps or just 1 big one.Maxus Pro-125 MigChicago Electric 90 amp DC flux-coreLincoln Electric AC 225 tombstoneO/A torchM/O mini-torch10 acres of flatland15 acres of holler
Reply:You mean the bleeder resistor ?Why a 40v capacitor ?
Reply:
Originally Posted by Bluewelders
You mean the bleeder resistor ?Why a 40v capacitor ?
Reply:I guess he just wanted to bleed the power out of the caps when he turned the welder off.He put a 150 ohm-10 watt and 160 ohm-7 watt resistor in series across the + & - of the cap.Which according to him,it should take about 1 minute to bring caps back to 0 volts.Why not a 40 volt.Maxus Pro-125 MigChicago Electric 90 amp DC flux-coreLincoln Electric AC 225 tombstoneO/A torchM/O mini-torch10 acres of flatland15 acres of holler
Reply:
Originally Posted by Pavinsteelman
. . . AC mig it will not work . . . You need polaarity control . . . or it comes out like crap .
Reply:You can buy 2 smaller caps cheaper than you can buy 1 large cap and the higher up in volts you go so does the price.I was looking at the schematics of the Lincoln easy-mig 140 and it has 1 large cap with 59,000 micro farads - 40 volts.I was using this as a guestimate as to just using 1 large cap instead of 2 smaller caps.The pricing on this stuff is.......some places charge out the a.. for this stuff while other places have the exact same thing for a whole lot less.Take a 100 amp bridge rectifier,one place wants $150 as to where another place with the exact same thing,$14 dollars.Last edited by dugndeep; 05-10-2011 at 06:00 PM.Maxus Pro-125 MigChicago Electric 90 amp DC flux-coreLincoln Electric AC 225 tombstoneO/A torchM/O mini-torch10 acres of flatland15 acres of holler
Reply:The resistor that discharges the capacitor can be any value that will drain the capacitor charge in a reasonable amount of time,usually 50-75 ohms at about 20watts.The welder with a bridge diode will charge the capacitor to 1.414 times the 31v AC voltage.That would be about 44v,which should be within the surge rating for a 40v capacitor.
Reply:Do these caps need to be volts dc,he doesn't say plus I can't see if they say 50 volts dc or not in the pics.Some caps just say v and some say vdc.I know the voltage coming off rectifier bank is dc but are caps specifically ac or dc?Last edited by dugndeep; 05-11-2011 at 03:13 PM.Maxus Pro-125 MigChicago Electric 90 amp DC flux-coreLincoln Electric AC 225 tombstoneO/A torchM/O mini-torch10 acres of flatland15 acres of holler
Reply:They would be DC.
Reply:Cap voltages are rated peak-to-peak. That's roughly 1.414 times the RMS AC voltage for an AC sinewave, or equal to a DC voltage.
Reply:Here's the rectifier and cap I think might work for this conversion.I need to get the 100 amp bridge rectifier ordered because it will take 5-6 weeks to get here from Hong Kong.It's only $10.77 and free shipping,one just like it from Windy Nation here in USA is $35 plus $12.99 shipping.The cap is from digi-key and it is $17 plus $11.69 shipping.I could probably get the cap cheaper off ebay but they want payment thru paypal and me and paypal are in disagreement over $7.99.I bought something back in 2009 that was suppose to be free shipping and when I bought it they said that I had missed the deadline on the free shipping and charged me for shipping anyway and just went ahead and took it out of my bank account.So my Paypal account is in limbo at the moment.
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Maxus Pro-125 MigChicago Electric 90 amp DC flux-coreLincoln Electric AC 225 tombstoneO/A torchM/O mini-torch10 acres of flatland15 acres of holler
Reply:I would like to go bigger than 47,000 uf on the cap but they get quite expensive.They do have a 100,000 uf for $24 but would that be too much.Because he used 2 caps,do you think he was trying to create a pi-filter?I know a pi-filter uses 2 caps but it needs an inductor too.Maxus Pro-125 MigChicago Electric 90 amp DC flux-coreLincoln Electric AC 225 tombstoneO/A torchM/O mini-torch10 acres of flatland15 acres of holler
Reply:I would maybe go with the 50 volt cap just to be sure on the voltage.Maxus Pro-125 MigChicago Electric 90 amp DC flux-coreLincoln Electric AC 225 tombstoneO/A torchM/O mini-torch10 acres of flatland15 acres of holler
Reply:The only problem I see in doing the conversion is room.I'm going to try & mount the rectifier in the back in front of the fan,maybe make a bracket & mount it to the top of the case and let it hang down in front of the fan so that it can get all the air it can.I have 1.5 inches between fan and transformer and 4.5 inches to work with in the front.The cap will be mounted in the front on it's side,that way all the final connections will be right there.I was going to put the little fan I used to have in the front back in there but just not enough room.
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Maxus Pro-125 MigChicago Electric 90 amp DC flux-coreLincoln Electric AC 225 tombstoneO/A torchM/O mini-torch10 acres of flatland15 acres of holler
Reply:
Originally Posted by dugndeep
I would like to go bigger than 47,000 uf on the cap but they get quite expensive.They do have a 100,000 uf for $24 but would that be too much.Because he used 2 caps,do you think he was trying to create a pi-filter?I know a pi-filter uses 2 caps but it needs an inductor too.
Reply:you welder may drop to ~85 amps from the diodes. but then the cap may make up for it..
Reply:Digi-key did have quite a few of the 47,000 uf 50V caps left, now they only got 2 so I'm probably going to have to pick a different one and go lower in microfarads.I'm trying to keep the conversion in the $30 to $40 dollar range.I'm just wondering if something in the 30,000 range would be alright.I just hate to go down in volts just to be on the safe side.I'm going to order the rectifier first,and then when I get it I will order the cap.Just have to wait and see what they have in stock then I reckon.I've already got some wire that I had laying around from another project,8 gauge.I would rather use some 10 gauge but since I have this it will do.
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Last edited by dugndeep; 05-15-2011 at 10:55 AM.Maxus Pro-125 MigChicago Electric 90 amp DC flux-coreLincoln Electric AC 225 tombstoneO/A torchM/O mini-torch10 acres of flatland15 acres of holler
Reply:Well I ordered the 100 amp bridge rectifier today,have to wait and see how long it takes to get here from Hong Kong.I'm paying $10.77 for it with free shipping.All I can find along the lines for a bleed resistor is 100 ohm at 20 watts.It is .98 cents.I'm just wondering if a 39,000 uf capacitor would be alright because they only have 2 of the 47,000 uf caps left and will probably be sold out by the time I get my rectifier.Other caps of about the same size, range from $30 to $60 dollars apiece.It seems it all depends on how many they have in stock,as the stock goes down the price goes up.Just have to wait and see whats available.Maxus Pro-125 MigChicago Electric 90 amp DC flux-coreLincoln Electric AC 225 tombstoneO/A torchM/O mini-torch10 acres of flatland15 acres of holler
Reply:The people who build the welders seem to think 40,000uf per 100 amps is the right amount.39,000 for 90 amps should work.100 ohms for the resistor should be alright,it will just take a little longer to run down.
Reply:
Originally Posted by Bluewelders
The people who build the welders seem to think 40,000uf per 100 amps is the right amount.39,000 for 90 amps should work.100 ohms for the resistor should be alright,it will just take a little longer to run down.
Reply:I appreciate all the input,I just like tinkering with things,hey,if it works,it works,if it don't, it don't,but I still appreciate all the help.Might be the excuse I've been looking for to buy a good welder if it blows lolThis started on the Ars Technica forum......some on there suggested that he use smaller caps just more of them,say 4 to 6-10,000uf caps.Maxus Pro-125 MigChicago Electric 90 amp DC flux-coreLincoln Electric AC 225 tombstoneO/A torchM/O mini-torch10 acres of flatland15 acres of holler
Reply:These bridge rectifiers are a dime a dozen in China and Japan so I don't hold much pumpkin on it lasting very long if at all.......I was just jealous too of everybody else upgrading their Harbor Freights and making them weld better,so I just couldn't sit around and take mine as is without trying to do something to make it a better welder.It should come from the factory as a DC welder to begin with.Flux core wire that I use, is specifically made to be run DCEN so it should at least be better at welding flux core wire.Last edited by dugndeep; 05-16-2011 at 10:45 PM.Maxus Pro-125 MigChicago Electric 90 amp DC flux-coreLincoln Electric AC 225 tombstoneO/A torchM/O mini-torch10 acres of flatland15 acres of holler
Reply:
Originally Posted by papaharley03
Maybe I'm off base here, Blue, but capacitance values are usually chosen based on the frequency they are supposed to pass or block. RF decoupling caps tend to be a hundred or so picofarads whereas caps for power line frequency filtering have much larger values, typically a few thousand microfarads. On the DC output of a welder, you should be using large capacitance to filter not only any line frequency trying ot sneak through, but any low frequency output level fluctuation. That's why I think they refer to this as an arc stabilization circuit.Just my humble opinion.Papa
Reply:Thanks for the help Bluewelders because all of that was over my head on trying to come up with some kind of answer to the capacitor size.I'm going to get a 1/8" thick piece of sheet metal and lay a few beads on it before the mod,then if the welder works after the mods,I will lay a few beads on that same piece of metal so we can see if penetration increased.I would like to use something else besides a flattened piece of copper pipe for the final connection from rectifier,cap to the clamp or gun.What about some kind of terminal strip or something?
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Last edited by dugndeep; 05-17-2011 at 08:40 AM.Maxus Pro-125 MigChicago Electric 90 amp DC flux-coreLincoln Electric AC 225 tombstoneO/A torchM/O mini-torch10 acres of flatland15 acres of holler |
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发表于 2021-9-1 23:19:13