Conversion to DP
Parts–
1* 10mm Red ring crimp
1 * Red butt splice,
450 mm length 1mm² lead
1 * 1m length 10mm² length welding cable ( if the earth lead is on poor condition you will need
and extra 1.5m to make a new earth lead)
2 * small dinse socket (10-25mm)
2 * small dinse plug (10-25mm)
Following crimps/terminals are for 10mm² welding cable
1 * 8mm ring
1 * 6mm ring
1* 10mm ring
Make up the following leads
+ve link cable use 400mm of 10mm² welding cable, fit 8mm ring crimp to one end and 6mm ring crimp to
the other.
Torch link cable use 350mm of 10mm² welding cable fit 10mm ring crimp to one end and a dinse plug to
the other.
Disconnect the welder from the mains.
Remove the side panels from the welder.
Disconnect the earth clamp from the earth lead and feed the lead back through the cable gland.
Remove the cable gland and blanking plug from the front panel.
Remove the torch connection lead from the brass threaded section of the torch and pull through the grom-
met in the centre panel.
Pass the ring crimp end of the new torch link cable through the grommet on the front of the welder and fit
the ring onto the brass threaded section.
Remove the thermal overload lead and torch connection lead from the rectifier plate, (if the overload lead is
crimped into the same ring crimp as the PCB connecting lead cut the overload lead next to the crimp), do
not remove the feed motor power lead from the plate.
Extend the thermal overload lead by 450mm and pass it through the grommet in the centre panel.
Trim the lead so that it will reach the brass threaded section of the torch.
Fit a 10mm ring crimp to the end of the lead and fit this onto the brass threaded section of the torch.
Fit 10-25mm Dinse panel sockets into the holes vacated by the cable gland and blanking plug.
Bolt the +ve link cable to the right hand dinse socket.
Pass the free end of +ve link lead through the grommet in the centre panel.
Bolt the +ve link cable to the rectifier +ve plate.
Remove the crimp connection between the choke and the earth lead.
Clean the insulation from the choke lead for 40mm and form into a ring around a 8mm bolt.
Bolt the newly form ring onto the left hand dinse socket.
Refit the earth clamp onto the earth lead.
Fit a Dinse plug on the earth lead and refit the earth clamp.
Label the left hand socket - and the right hand socket +.
Ensure all connections are tight and the internal cables are routed neatly, check they are not touching any
mains connection or hard against any sharp edges, you may need to use cable ties to secure the cables.
Refit cover
For gasless operation fit the earth lead into the right hand socket and the torch connection lead to the left
hand socket.
For gas operation fit the earth lead into the left hand socket and the torch connection lead to the right hand
socket.
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