Campbell Hausfeld Welder Flux Core 80 Parts

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Campbell Hausfeld Welder Flux Core 80 PartsCampbell Hausfeld Welder Flux Core 80 Parts

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So in the spirit of the harbor freight modding thread, I got inspired / motivated to try it with my flux core 80, especially since this is now my backup machine. Insteald of buying new parts, I decided to try and use various random parts I have laying around. Dont ask why I have hundreds of capacitors, I dont really have a good reason lol.

Anyways, my first attempt was to just add 3 capacitors and see how the arc quality changed, Unfortunately I only got a ~30 second test with wirespeed that was about triple what it was before adding the caps. So not a good test at all. I also found the wire I uses was VERY small for the current in question. I thought ~8 inches of 14 guage stranded wire would not be an issue in such a low power unit, with only 3 caps, but It was small enough that the heating got the insulation tacky hot with 30 second test weld onto some scrap exhaust tubing. Phase two will be bigger wire, and adding a few diodes in series with the wire feed motor in order to drop.7v per diode in the hopes of slowing the wirespeed back down to a usable range.

I might go for a phase 3 and bump it up to 6 caps depensing on how the arc 'feels' full size images: Last edited by jdchmiel; at 10:29 PM. Reason: img links. I used to have that welder. As I recall the transformer output fed into the diode bank and from there to reactor (on top of the transformer) then out to the welding gun. Yes, you could likely benefit from inserting your capacitor(s) after the diode bank and before reactor. I'm surprised your wire feed speed rose so much. Originally, under welding conditions, you likely have about 22 volts or so at the reactor output.

Adding in a capacitor might raise the output voltage to a maximum of 30 volts with minumal load. Adding in a series of diodes to the wire feeding the wire-speed motor should solve that wire-speed issue. It's possible you could cause diodes to pop by adding too much capacitance on the output of the diode bridge. The reason is that, for a given output current, as the capacitance increases the conduction time of the diodes becomes shorter since conduction will only occur when the anode of the diode is at least 0.7 volts higher than the voltage on the capacitor bank.

If the capacitance is high enough that the voltage on the capacitor bank remains near the peak voltage out of the diode bridge (which is, after all, what you are trying to accomplish by adding the caps), the conduction time could become short enough and the peak current high enough that the diodes can't handle the heat generated by the current pulses. I have no idea whether this could become a problem with the amount of capacitance you can practically install in your welder. How much capacitance are you installing? Not trying to discourage you from experimentation, but be prepared to buy replacement (or higher current rated) diodes if you increase capacitance too much. The stress on the diodes is least for an inductive load because in that case the diodes conduct over a large portion of the waveform and the peak currents are low. There is nothing inherently bad about capacitors on the output of the diode bridge provided the transformer and diodes are selected for that service.

I fear that a unit like the C-H Flux-Core 80 is designed with minimally conservative component ratings in order to meet their price point and there may not be much headroom for the changes in operating conditions that will result from your mods. If you are set up for it, you might consider measuring temperature on the heat sink adjacent to a diode for some relatively fixed welding current and duty cycle with and without the caps. It might tell you if you are getting into a problem area. (But be careful because the heat sinks will be electrically hot.) Lots of fairly inexpensive DVMs have temperature measuring capability these days using thermocouples. Non-contact thermometers that read infrared radiation are also getting very cheap these days - way below $100.

You don't need precision since you are only interested in the relative change, not the absolute temperature.