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Adding Bridge Rectifier 300A/1600V High Power Single Phase Diode to LINCOLN AC 225 Welder 

DJ Rowe
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29 окт 2024

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Комментарии : 96   
@michaeltillman958
@michaeltillman958 3 года назад
The best explanation of this thus far. Thank you. I also agree, I watched the other videos depicting this and some of them were wired completely wrong. Thanks again for your time and effort.
@djrowe10
@djrowe10 3 года назад
Thanks for watching and responding positively.
@RJB_FixinStuff
@RJB_FixinStuff Год назад
You are correct in that it doesn't make It DC but incorrect in that it compresses it. It will actually invert the negative side of the wave and over lap the positive side of the wave which will give you pulsed DC. But good video.
@djrowe10
@djrowe10 Год назад
I get that, but it is hard to explain in any other way about that to those not well educated on electronic theory and practice. Thanks for watching! 👍
@notcharles
@notcharles Год назад
A/C has two conductors. They are neither Positive, or Negative - they ALTERNATE so many times per second. The bridge Rectifier effectively converts these alternating pulses to Direct Pulses - e.g. 'direct current or DC' where one conductor is ALWAYS positive (when conducting) and the other is ALWAYS Negative (when conducting). X'tee times a second, the output approaches ZERO, but the current output is always Direct, DC. With a CHOKE (in series in the + lead) and A (suitable) Capacitor across the two DC conductors, one can all but eliminate the cyclical voltage drop which makes things weld better. So far, I've yet to see a detailed description of such a setup (specs on capacitor(s) detailed construction of a suitable/serviceable choke) or I'd share!
@djrowe10
@djrowe10 Год назад
There is a great video of this demonstration from a genius young man in India. I will try to find and link it to this after I get his permission.
@christophervillanti1417
@christophervillanti1417 3 года назад
By definition a rectifier converts AC to DC. In this case it's pulsating DC. You can smooth out the ripple with a CRC or a CLC network. The compressed AC line that you are talking about is the ripple. If you switch your meter to DC you will see the DC component. Check out this video: ru-vid.com/video/%D0%B2%D0%B8%D0%B4%D0%B5%D0%BE-p5DLEpDRBYk.html
@djrowe10
@djrowe10 3 года назад
thanks
@wwrite
@wwrite 3 года назад
As an electronics engineer I can confirm what Christopher said as well. Check out the topic full wave bridge rectifier.
@djrowe10
@djrowe10 3 года назад
Thanks also.
@joeydelmarsjr.646
@joeydelmarsjr.646 4 года назад
im doing to same thing. BUT you might want use the positive off the bridge recruiter as your clamp/ground and negative for your weld stick. ALSO you want 23k-50k uf caps and a bleed resister in parallel. and if you can find a microwave transformer core as an inductor. also some LPD-50 quick connects would be nice too
@djrowe10
@djrowe10 3 года назад
Yes, I have found a microwave transformer for parts.
@joeydelmarsjr.646
@joeydelmarsjr.646 3 года назад
@@djrowe10 how is it holding up any updates how is it working. good?
@djrowe10
@djrowe10 3 года назад
@@joeydelmarsjr.646 It seems to weld better or about the same with less spatter and has held up ok so far but I have only used 3 times since converting. I mainly use mig or tig and my tig machine does stick in DC. It is a project in progress to say the least and needs fine tuned still. Good Luck!
@joeydelmarsjr.646
@joeydelmarsjr.646 3 года назад
@@djrowe10 I'm thinking of getting a primeweld 225
@josephhreha8465
@josephhreha8465 2 года назад
@Joey Del Mars Jr. Do the capacitors go on both leads or just the electrode? And where does the transformer fall in line? Before or after caps
@AvocaSingleTrack
@AvocaSingleTrack Год назад
That is not what that rectifier does. It doesn't suppress anything as you describe. It takes AC input and outputs pulsating DC. If you add a capacitor to that pulsating DC output, you can get a fairly smooth DC output
@djrowe10
@djrowe10 Год назад
Because I did not use anything except the bridge rectifier is the reason I stated it is not a true DC current. Thanks for sharing.
@scooter1391
@scooter1391 12 дней назад
here's where I have and issue with this A bridge rectifier, also known as a diode bridge, converts alternating current (AC) to direct current (DC). Bridge rectifiers are used in many electrical products and workplace appliances, and are a key component in power supplies (battery chargers use them) Yes, bridge rectifiers are used in battery chargers: How they work Bridge rectifiers convert alternating current (AC) from the mains power to direct current (DC) that can be used to charge a battery. Other components Battery chargers also include a transformer to step down voltage and an ammeter to monitor the charging current
@djrowe10
@djrowe10 10 дней назад
You got it! I just wanted to show a quick method on how to convert this AC welder. Thanks for watching! 👍
@crazyDIYguy
@crazyDIYguy 3 года назад
If you want cleaner DC you can make an inductor "Choke" using thick wire and an alternator core, microwave transformer core, etc. Also you can wire a capacitor in parallel on the output leads something like 40,000uf 150-200volt rated... Just what I've picked up reading so far.
@djrowe10
@djrowe10 3 года назад
I've got a couple microwaves but haven't tore apart yet to get transformers out. One of these days but haven't used that welder for a long time now.
@josephhreha8465
@josephhreha8465 2 года назад
Do you wire the capacitor on the stick lead only? And would you get a cleaner DC wave by using the positive as your clamp and negative as your electrode?
@crazyDIYguy
@crazyDIYguy 2 года назад
@@josephhreha8465 I tried reverse polarity and really got no difference, (negative lead to the stick side) I would just keep it positive electrode. Your capacitor needs to be rated higher than your voltage, there's a white stripe down the side of your capacitor, that's the negative side which attaches to ground clamp wire between your diode and your ground clamp, the positive lead on your capacitor attaches between your electrode and your diode. Mine went diode first, then inductor (wired in series) on either the positive or the negative side it doesn't matter. Then my bank of capacitors the positive leads wired to the electrode side and the negative leads wired to the ground clamp side.
@crazyDIYguy
@crazyDIYguy 2 года назад
Don't worry if you get it wrong, your capacitor will explode and shoot hot oil everywhere. Along with a huge cloud of smoke and steam. 😎😆😆😆 (Ask me how I know, lmao)
@josephhreha8465
@josephhreha8465 2 года назад
@@crazyDIYguy 🤣. Tenfour. I appreciate the info. Building mine today
@slick1rick1
@slick1rick1 4 года назад
A full wave bridge rectifier converts AC to DC, do not tell people otherwise.
@djrowe10
@djrowe10 4 года назад
I let people make comments on my videos and you are entitled to your opinion. If a $20 wave rectifier made an AC welder into a DC welder then Lincoln and Miller Welding must be doing something wrong I guess.
@ryanburch26
@ryanburch26 3 года назад
Dude you're definitely misinformed about electricity as a whole. How do you have positive and negative if it's not DC
@brandonh6326
@brandonh6326 3 года назад
@@djrowe10 The bridge rectifier does output DC current (as it is no longer alternating), but the power signal is not a clean straight line. The power signal will have significant ripple between the peak voltage and zero volts (but does not cross zero, as that would make it AC). Capacitors (in parallel) are needed to smooth out the valleys in the signal in order to "clean up" the dirty DC signal produced by the bridge rectifier. The capacitors will charge up when the voltage peaks and then discharge when the voltage drops, providing the desired smoothing effect to get a cleaner DC power signal. Someone attempting a DC conversion on an AC welder will want a bridge rectifier capable of handling the max number of amps produced by the welder with a margin of error (more margin of error the better, but also more cost). They'll need to provide good heat sinking (preferably with a dedicated fan as well) so that the bridge rectifier can stay cool. They'll also need high-capacitance capacitors (they will be physically large and probably fairly expensive). The capacitors should be wired in parallel with the DC side coming out of the bridge rectifier. A bleed resistor should be wired across the DC lines for safety to discharge the capacitors and to prevent the machine from trying to weld/spark when it's otherwise powered off.
@djrowe10
@djrowe10 3 года назад
Thanks.
@djrowe10
@djrowe10 3 года назад
I agree with your response and is why my message is that just simply adding a wave rectifier alone doesn't provide clean 100% DC conversion alone. My video contains none of the other needed things to make a clear pure signal in DC from AC. There is an actual electic engeneer on RU-vid who shows all parts and how to do what you listed in his video.
@magnatron7734
@magnatron7734 3 года назад
Good vid, I understand what you are saying.
@djrowe10
@djrowe10 3 года назад
Glad to help.
@jaimecastilloduarte7590
@jaimecastilloduarte7590 2 года назад
Great Bro. 🙋🏻‍♂️🇵🇪
@reloadnorth7722
@reloadnorth7722 2 года назад
My dad got his Lincoln 225 in 1975. He gave it to me a couple years ago. It still works great, but needs a fan replacing. I just might try this. Great video. Can anyone tell me if dielectric grease could be used on the heat sink. Thanks, stay safe.
@djrowe10
@djrowe10 2 года назад
You can buy actual heat sink grease on amazon or use white lithium grease if in a pinch to test it out. Good luck with the project!👍
@redraven9540
@redraven9540 10 месяцев назад
You got a pure DC unfiltered voltage. On the Graetz you lose about 3 - 5 Volts, which is negligible. Do not add any capacitors, the currents are too high, they are unnecessary... you have certainly upgraded your device to a higher class 👍
@djrowe10
@djrowe10 10 месяцев назад
Welding is an automotive repair necessity. Thanks for watching. 👍
@jafinch78
@jafinch78 Год назад
I'm trying to learn how to use the Prius Gen3 inverter h-bridge for generic rectified inputs (like from a generator or multiple generators) for optional 120, 208-240 and 460-480 pure sine wave outputs since seems like is feasible with the properly designed controller. I was also wondering what would be the best way to design a circuit for options to output as a welder power supply besides feedback for CV or CC and frequency control, in particular a high power offset circuit so for use in aluminum welding, i.e. an offset square wave so can select a range of DCEP or DCEN ratios. Kind of off topic, though neat to see your design and got me thinking about since on the topic of assessing options before getting into the intricate details of the circuit modeling before some hands on experimental testing before scaling up the actual controller(s).
@djrowe10
@djrowe10 Год назад
That sounds awesome! 👍
@notcharles
@notcharles Год назад
Well, bless you heart.
@jafinch78
@jafinch78 Год назад
@@notcharles You know, I finally actually posted on the openinverter forum this vision of a project. Wound up investing in a gen 2 prius as well and three inverter converter assemblies to work with since those parts inside like the IGBT H Bridge inverter, converter and other parts seemed more modularized. Zombieverter seems better maybe for the gen 3 as a plug and play option maybe with only coding required to do and openinverter I found has been demonstrated by the creator to produce noisy 220VAC mains output and he notes that did fry some equipment that I guess needs the pure since wave output. I last left off wondering about filtering the signal to remove the harmonics so to make a stable pure since wave output to start with in a more compact way to avoid the larger like buzzbox maybe size transformer cores as a cost effective way to wind an inductor. Maybe multiple microwave oven transformer cores wound as inductors might be correct. I studied the impedance theory a little more as well last night actually to better understand the reactance at the different frequencies coupled with resistance to determine impedance where impedance is basically resistance at different frequencies. Lots to still learn, though slow turtle pace style moving forward. Thanks for the kinds words to remind and inspire.
@djrowe10
@djrowe10 8 месяцев назад
Sorry for long delay in response as I had to look into the multiple microwave transformers which took a few months to gather the theoretical information and feel that yes it would be a better possible method. If you have found out that to be true then let me know how it works out. I may try that as well and make a video if so. 👍
@jafinch78
@jafinch78 8 месяцев назад
Thanks for the response. Similarly, I've not worked on in a few, though someone else has recently inquired about the inverter-converter assembly design as a universal pure sine wave inverter. I mentioned either maybe like an old transformer design welding machine as-is using a winding as an inductor or rewinding or rewinding multiple MOT's. Just been busy with two many things, including advocacy work. @@djrowe10
@randolphsnyder1505
@randolphsnyder1505 7 месяцев назад
If you are using 7018 rod, I prefer stinger to be negative
@djrowe10
@djrowe10 7 месяцев назад
It's something how polarity really makes a difference
@mattlong4102
@mattlong4102 Год назад
if you add a high voltage capacitor after the rectifier it will give you dc power if it is sized appropriately.
@djrowe10
@djrowe10 Год назад
Thanks for watching 👍
@Lou-eye
@Lou-eye 5 месяцев назад
What is advantages of making the welder DC over AC ?
@djrowe10
@djrowe10 5 месяцев назад
I really was just looking at how to do it quickly and without a bunch of other complicated elecronic parts. I have 2 DC stick/tig machines also. But DC is a better type of welding overall for better performance in relation to penetration, appearance, and other things that when this AC welder was made in 1990 was much cheaper then a DC unit that could cost up to a thousand dollars. AC has it's use in a small limited type of welding and I suggest you go online and study up and learn more about DC and AC welding if you are getting in the welding trade. Also youtube has many master welder instructors that have dozens of videos about welding. Good luck with your project! 👍
@mikef-gi2dg
@mikef-gi2dg 2 года назад
I have a ac225 buzz box. I purchased it in 1990. It sat for 25+ years unused. I got 220v in my garage, last summer. I plugged it in, it works beautifully. I considered these rectifier bridge add on's for dc welding. But after reviewing my Bridge rectifier training on JG The Organic Chemistry Tour, I understand why Lincoln charges what they do for an AC?DC BUZZ BOX. I am NOT a pro welder by any stretch of imagination, but if I need DC, it's better to buy a box that has DC. These rectifier add on's don't have the current and voltage regulation needed for a good signal. But I am sure MANY will be able to make it work for their needs, JUST FINE. If I could sell my AC BUZZ BOX, I would fork over the cash and buy the AC/DC version, or buy a DC capable box. If I can find out what stick to use to weld Aluminum with AC, i keep what I got. Just sayin!
@djrowe10
@djrowe10 2 года назад
This modification is just a bandaid for sure. I sold my AC/DC Lincoln welder and just bought 2 separate welders one portable DC and this AC box. I can get you the part number for a good AC aluminium welding rod. Just let me look in the shop next time I'm there.
@mikef-gi2dg
@mikef-gi2dg 2 года назад
@@djrowe10 Thanks for any ac rod assist you might find. Along with my Buzz Box I got a Lincoln 110v sp-125+. Both over 30+ years old. I want to take advantage of new 220v in my garage. Looking to get anther box, probably a MP combination, with a spool gun. Just want to be able to do some light aluminum, and some sheet metal auto repair. Maybe on 20 years I'll be a BAD A Welder!
@djrowe10
@djrowe10 2 года назад
I looked at my shelf and have a box of something from Amazon supplier called SUA welding technologies. It is OK...will work in a bind but not best out there. Will add link at bottom. Sorry that I couldn't find my blue demon rod because it is the best. You can also call blue demon directly and ask them what rod you should get. They are a good company. If not try the amazon special I found recently. Aluminum Electrode - E4043 Stick Electrode - 14" x 1/8" - (1 Lb) www.amazon.com/dp/B074W9R9Z7/ref=cm_sw_r_cp_apan_glt_i_ZS96AX8P9H846JZCY5WZ?_encoding=UTF8&psc=1
@jamesjohnson5700
@jamesjohnson5700 2 года назад
How many watts can it handle?
@mikef-gi2dg
@mikef-gi2dg 2 года назад
@@djrowe10 Thanks for the info....My new lincoln l31mp just don't have what it takes to strike an arc with 3/32 4043 rod...just for giggles I cranked up the ac225 and it can't start an arc either....it was a long shot either way...time for a spool gun.
@marioserra4383
@marioserra4383 3 года назад
Good job
@djrowe10
@djrowe10 3 года назад
Thanks.
@tedjomiarso
@tedjomiarso 3 года назад
If you add a switch n a 300A relay would it become switchable ac/dc weld sir? Appreciated your advice.
@djrowe10
@djrowe10 3 года назад
I cannot say for certain that it would 100% work as I am not sure about what exact parts you would use. Plus I am not an electrical engineer but I do think it is possible. If you try it let me know if it works.
@travisfeltwater5664
@travisfeltwater5664 3 года назад
Just attached rectifier to quick connects so you can attach it or deattach from work lead or electrode lead outside machine
@tedjomiarso
@tedjomiarso 3 года назад
@@travisfeltwater5664 do you think by adding bridge rectifier it's dc enough or do we need to add an elco as well to make it more smooth?
@jordannaumceski2269
@jordannaumceski2269 2 года назад
I wanted to ask about rectifier reliability. Is it good or not ? Because it is noname i do not know if it is reliable or not. I am hoping that you are using the welder and would like to share som experience about the rectifier. Thank you
@djrowe10
@djrowe10 2 года назад
Seems like only one to find online. Back not too long ago I would go to radio shack and get my electronics. Now we have to rely on ebay and amazon unfortunately. Hasn't melted or burned up yet after some mild use. Haven't put machine to full amp setting just 90-120 so far and welds a bit better. I have a DC stick direct current 220amp machine for heavy steel.
@jordannaumceski2269
@jordannaumceski2269 2 года назад
@@djrowe10 Thanks a lot
@dalebourgeois9851
@dalebourgeois9851 Год назад
Hello, Thankyou for sharing this video. Your rectifier for your welder, where did you get yours? because most of what I see online doesn't have the positive or negative mark's on them. Thankyou Again
@djrowe10
@djrowe10 Год назад
I have added the parts used in the description drop down box. You have to click on the more info link under description box to see these products Amazon links. Thanks for watching.
@flowtime8673
@flowtime8673 3 года назад
is it possible to weld with one transformer and 100amps Rectifier
@djrowe10
@djrowe10 3 года назад
No 100 amps is not enough generally. You need to have the amps safely higher then amps of welder used to not overheat and destroy the unit. So if your welder is under 100 amps then that may work.
@jamesjohnson5700
@jamesjohnson5700 2 года назад
How many watts can this handle?
@djrowe10
@djrowe10 2 года назад
Not sure if the manufacturer lists watts as welders operate on amps/volts. This 300 amps or 1600V which converted to watts mathematically is 480,000 watts. Good luck with your project! 👍
@jamesjohnson5700
@jamesjohnson5700 2 года назад
@@djrowe10 Thanks I really appreciate it
@jamesjohnson5700
@jamesjohnson5700 2 года назад
@@djrowe10 so it I add 10 10amp 12volts lithium battery packs to the back of my solar panel connect it to motherboard with xt90 connector then connect that to 100amp mppt controller to my solar panel would that work?
@jimbauer6822
@jimbauer6822 Год назад
Rectifier doesn't compress anything it removes half the sign wave cuts the ac in half
@djrowe10
@djrowe10 Год назад
Thanks for sharing 👍
@schsch2390
@schsch2390 Год назад
A single rectifier (called a half wave rectifier), yes but djrowe2 is using a bridge or full wave rectifier which has 4 rectifiers so there is only a few percent loss in the rectifier itself.
@djrowe10
@djrowe10 8 месяцев назад
I really appreciate all the viewer comments! 👍
@alihadi1978
@alihadi1978 3 года назад
تحويل مكينة لحام قديمه من تيار متردد ac إلى تيار مستمر dc
@djrowe10
@djrowe10 3 года назад
I understand this Arabic language reply is saying "converting old welder from AC to DC". Just translating to English for some readers. Thanks.
@alihadi1978
@alihadi1978 3 года назад
@@djrowe10 Thank you, yes, right
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