The welder is back to its original configuration and is working. The rectifier that I added to the system to make the welder DCEN failed. A new rectifier is under $20. I also posted this on the welding web. One of the responses that I got there explained why the rectifier failed. When you use a 3 phase rectifier in a single phase circuit you lose 1/3 of the amp capacity. So the rectifier was only good for 100 amps. Not 150 amps. My welder puts out over 100 amps on max power. Thus the failure.
The new 150a 1600v single phase rectifier arrived yesterday and I got it installed this afternoon. My welder is back working with virtually no splatter and a nice bead. Have several welding projects that I need to complete.
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