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Converting a AC welder

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AJ

08-22-2000 05:51:57




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I have an old AC welder and was wondering if it worthwhile or feasible to convert it to run DC.
Has as anyone made such a conversion and how did it work out?




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MikeH-Tx

08-23-2000 07:00:16




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 Re: Converting a AC welder in reply to AJ, 08-22-2000 05:51:57  
I found an electrode holder with a built in diode, for about $50. Connects to the AC electrode holder. Haven't tried it yet, though. If I remember right, it was ordered from Sears Auto Store catalog.



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carl

08-22-2000 17:13:05




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 Re: Converting a AC welder in reply to AJ, 08-22-2000 05:51:57  
Could someone PLEASE post a schematic,bill of materials and instructions for those of us who are electrically challenged?



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Tyler(WA)

08-22-2000 06:14:43




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 Re: Converting a AC welder in reply to AJ, 08-22-2000 05:51:57  
I'm going to do that to mine. There's plenty of room under the cover and the cost should be under $75. The diodes are about $10 ea and heat sinks should be about the same. Add a couple new cable sockets and you're done. There's no magic to converting AC to DC.

You can order the diodes with comon anode or cathode, you'll want two each. Most of your "settings" will be by guess and by golly but for what it's worth, DC voltage through a full wave rectifier is 1.44 times the AC input voltage.

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Roger

08-30-2000 19:43:13




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 Re: Re: Converting a AC welder in reply to Tyler(WA), 08-22-2000 06:14:43  
In addition to a full wave bridge rectifier you will also need to add a choke coil in series. Other wise you will find the pulsating DC (120Hz) to be unsable for running DC only rods. The surplus center out in Nebraska used to have these in their catalog. I have not seen one for a while so I don't know if they are still around. When I converted my welder I used an old transformer core to wind my own. It was a lot of fooling around. I would reccomend buying one

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Fred OH

08-22-2000 08:15:51




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 Re: Re: Converting a AC welder in reply to Tyler(WA), 08-22-2000 06:14:43  
Tyler, you might have to add that you would have to de-rate the duty cycle of the welder just a little too. L8R----Fred



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