sip ideal 150 problem

[paddy1981]

hi can some body give me some advice my mig has been working very well untill today i pluged it in and got nothing but a fast clicking from the contactor i think thats what its called the mains power goes to it then into the mig it is a large electro magnet when turned on it just clicks and there is no power to the welding wire and the gas wont stop any help would be most welcome thanks paddy

 

[rtbcomp]

Welcome to the forum.

Does it click as soon as you switch it on or when you pull the trigger?

Is it a continuous clicking?

Does the wire try to feed?

 

[paddy1981]

hi wire feeds ok it clicks in and out on it own it continues to click even with the tourch disconected

 

[rtbcomp]

Does it click as soon as you switch it on or when you pull the trigger?

 

[paddy1981]

as soon as switched on

 

[mike 109444]

Sounds like the contactor is reciving a faulse trigger from the pcb. Will try and find a circuit diagram of the pcb to see if I/we can point you to suspect part/s (prob if there is a relay on pcb could be that is sticking ON) Do you have a Pic of pcb?

 

[mike 109444]

Just been looking at a very poor diagram! Check to see if you have the "Spot" or "Stitch" setting selected?

 

[paddy1981]

hi doesnt seem to matter if its on spot or stitch setting

 

[paddy1981]

the pcb has no relays and the fuse is ok

 

[mike 109444]

What are you like with a circuit diagram and a meter?

 

[paddy1981]

not a problem what you got in mind and thank you for the help

 

[mike 109444]

If this is your circuit then the part of the circuit highlighted in red is what activates the contactor (contactor is just a BIG relay!) The red line is the power to the coil in the contactor. Something is activating this. May be something on the pcb that the timer boad plug (12) plugs into. Sorry about the image quality had to make into jpeg to get it to load. Will post BMP image if it will fit

 

[mike 109444]

Hope this image is a bit clearer. This was the orignal image I copied from a post by another member ("Piero" from 12-5-2012). I think he scaned the diagram he had but as it is a jpeg it is not the best quality.
Looking at the diagram one of the outputs of item 7 (aux transformer) is 48vAC (bit fuzzy!) this feeds to the coil in the contactor (red line) then through the thermal cut out item 13 (mounted to the main transformer?) This then feeds on to pin 2 of item 12 (multi pin plug going into timer board) That was why I thought if you had a fault with one of the timer (spot/stitch) circuits, say a relay stuck that could cause the contactor to be energised. Would need a circuit diagram of the timer pcb to follow this up (or at a pinch a pic of both sides of the pcb, but not so easy to work with!).
One though if you disconnect the wire going onto pin 3 of plug 12 and that stops the contactor triggering (which it should) that would imply that the fault is in the timer. If it still does it then there is probably a short in the wiring from the contactor via the cut out and to the pin3 of plug 12.

 

[mike 109444]

If it is down to the pcb all may not be lost as looking through the SIP posts I came across this recent post http://www.mig-welding.co.uk/forum/showthread.php?t=35726 As you can see at the bottom of the post "Big Miggy" was able to get a replacement pcb for £44 !! You'd prb pay more for one of the newer (small) sip machine pcbs !!

 

[paddy1981]

had a look today and found that if i disconect the grey wire from the pcd that all the buzzing from the gas valve stops and the contactor stops jumping in and out ive atken some pics of the pcd but it looks fine no burned circuits also found that if i disconnect the gas valve relay the contactor stops jumping in and out too will put pics on soon

 

[mike 109444]

If the relay (16) is of the semi clear cover type then you could try removing it's cover and cleaning the contacts on all the points at a pinch use wd 40 on some stiff paper and pull through the contacts. Failing that it could be a duff semiconductor on pcb. Pics req'ed

 

[paddy1981]

http://www.mig-welding.co.uk/forum/...ent.php?attachmentid=31821&stc=1&d=1355097500

 

[paddy1981]

cant see any clear relays but have managed to get photos uploaded

 

[Superbad]

This might be of some help
http://www.mig-welding.co.uk/forum/showthread.php?t=35329&page=4

 

[mike 109444]

This might be of some help
http://www.mig-welding.co.uk/forum/showthread.php?t=35329&page=4

Yes it might have helped if Licker had come back to say replacing thoes devices had or had not fixed his machine!!
Any Hoo Paddy1981 if you follow that link it shows very similar problem and if you look on your pcb you willsee you have several similar devices. Can you get the numbers that are printed on them.
Ps does that board have on the ends of it's leads a multi pin plug or socket that ties up with whats on the diagram item 12?