Converting Telwin 180/2 Turbo to Euro torch

[Willyswelder]

Hello. I just found out that my trusty Telwin 180/2 Turbo needed a new torch. I ordered a Twin 15, which was supposed to fit my machine. The old torch had just one wire. The new had two. One long and one short. The gas line fits, but I can not seem to figure out where to connect the cables. Been trawling the net, with no luck. Hope someone can help. Thanks

 

[a111r]

Welcome!
Essentially this is same model as my old Sealey 195. One wire connects via terminal 7 on the PCB, the other to DC +ve on the bridge rectifier.

The old torch would have shorted the single wire to the torch gas block / valve (dc +ve), whereas your replacement only contains a micro switch to join the two wires.
Diagram is here:
https://www.mig-welding.co.uk/forum/threads/sealy-supermig-185-pcb-repair-help.53483/

 

[Willyswelder]

Thank You! I am a total newbie. Where is the bridge rectifier?

Thanks

 

[a111r]

It's bottom right. One of the plates has the thick torch (DC +ve) wire connected to it, this is the one you want.

See if you get any other responses, as I could be wrong about the 2 wires!

 

[eddie49]

It's bottom right. One of the plates has the thick torch (DC +ve) wire connected to it, this is the one you want. See if you get any other responses, as I could be wrong about the 2 wires!

I am sure that that is correct. Originally the switch in a single-wire torch would make contact with the brass block/swan neck, which is the positive welder output. Now having two wires and a real microswitch, you still need that positive rectifier output to correctly drive the relay logic on the PCB.
[ In this 2-wire torch situation, you have the option of making the torch negative to use no-gas flux-core wire, but the PCB will still get the correct positive signal from the trigger switch.]

 

[Willyswelder]

Thank You very much! As i found the #7 terminal is the one that originally goes to the torch, and as I found out there is a free terminal on the bridge rectifier.

This seems to be correct then? See picture.

Best regards, Lars

 

[a111r]

Not easy to tell from the photo but I think that's the 'wrong side'. As in dc -ve. That's going to the inductor (like a big transformer) then on to the earth lead.

You need to tap into the top bolted dc +ve connection, or any free spade on it. I could be wrong, blame my eyes...

 

[eddie49]

Lars, yes, that is correct. In the centre of the rectifier there is a heavy steel bar that is bolted to the black cable, going to the torch. There is also a thinner tab, on the same central bolt, which has a soldered connection to the blue circular component ( a spike suppressor ), and finally two red wires. That is where you need to connect the 2nd thin wire from the Euro torch.
[ The negative, as mentioned by a111r, is the U-shaped strap linking the two outer plates of the rectifier. It is bolted to the solid winding wire of the inductor, which sits on top of the main transformer.]

 

[Willyswelder]

It worked! I plugged it to the terminal mentioned. Thanks for all the help! Tomorrow I finally get to start welding on the Brewing table .

 

[Brice52]

Hi guy's my apologies for my english and if that's not the good place to post my question. I'm novice too i got the same mig 180/2 turbo and i would like to put an euro torch on it but that's not totally clear i try to understand 'your precedent answers but still a bit confuse someone is able to give me some clear explication? Maybe pictures will be the must thank's anyway cheers

 

[johnrev]

Since nobody else has chipped in I'll try to explain. I don't have this welder but I think most machines are very similar.
The old torch had one thin wire which disappears into the machine. One of the Euro connector wires (either one) should be connected to this wire.
The other Euro connector thin wire needs to be connected to the main welding power cable which goes up to the torch from the welder. This is the thick black wire and it will disappear into the welder somewhere.
You could connect your thin wire to this power cable anywhere that's easiest. It may be simplest to use a crimp type connector which fits over the Euro threaded section so it's trapped by the fixing nut.
If this is not convenient you can fix your wire at the other end of the power cable. For this you need to open the welder case and follow this cable down inside. It will be connected to the rectifier which is one or more aluminium plates with other thick wires bolted to it. You must connect your thin wire to the same point as the thick cable. From what is said above it seems there is already spade terminals available that you can connect to. All you need is a suitable crimp on connector and push your wire on. If there isn't a spare terminal on your machine you can undo the bolt that's fixing the cable and connect to that. These bolts need to be tight as they carry the welding current so be sure it's well tightened.
Hope this may be of some help.

John

 

[Roberto_San]

Hello Willyswelder, I need to know if you could help me, I plan to install a new torch on my Telmig 180/2, I need if you can tell me what the correct connection for the European connector would be since I don't know anything about the subject and you mentioned that your modification worked.
Please contact san.roberto.1990@gmail.com
or whatsapp +56957179622. greetings from chile.

 

[Roberto_San]

Como nadie más ha colaborado, intentaré explicarlo. No tengo esta soldadora, pero creo que la mayoría de las máquinas son muy similares.
La vieja antorcha tenía un cable delgado que se desvanecía en la máquina. Uno de los cables del conector europeo (cualquiera de los dos) debe conectarse a este cable.
El otro cable delgado del conector europeo debe conectarse al cable de alimentación principal de soldadura que va desde la soldadora hasta la antorcha. Este es el cable negro grueso y desaparecerá en algún lugar de la soldadora.
Puede conectar el cable fino a este cable de alimentación en cualquier lugar que le resulte más fácil. Puede resultar más sencillo utilizar un conector de tipo crimp que se ajuste a la sección roscada europea de modo que quede atrapado por la tuerca de fijación.
Si esto no es conveniente, puede fijar el cable en el otro extremo del cable de alimentación. Para ello, debe abrir la carcasa de la soldadora y seguir este cable hacia el interior. Se conectará al rectificador, que es una o más placas de aluminio con otros cables gruesos atornillados a él. Debe conectar el cable fino al mismo punto que el cable grueso. Por lo que se dijo anteriormente, parece que ya hay terminales de horquilla disponibles a los que puede conectarlo. Todo lo que necesita es un conector de crimpado adecuado y empujar el cable. Si no hay un terminal de repuesto en su máquina, puede deshacer el perno que fija el cable y conectarlo. Estos pernos deben estar apretados ya que transportan la corriente de soldadura, así que asegúrese de que estén bien apretados.
Espero que esto pueda ser de alguna ayuda.

John

necesito saber si me podrías ayudar, tengo pensado instalar una nueva antorcha en mi Telmig 180/2, necesito si me puedes decir cual sería la conexión correcta para el conector europeo ya que no se nada del tema y tu mencionaste que tu modificación funcionó.
Por favor contactar a san.roberto.1990@gmail.com
o whatsapp +56957179622. saludos desde chile

 

[Roberto_San]

Since nobody else has chipped in I'll try to explain. I don't have this welder but I think most machines are very similar.
The old torch had one thin wire which disappears into the machine. One of the Euro connector wires (either one) should be connected to this wire.
The other Euro connector thin wire needs to be connected to the main welding power cable which goes up to the torch from the welder. This is the thick black wire and it will disappear into the welder somewhere.
You could connect your thin wire to this power cable anywhere that's easiest. It may be simplest to use a crimp type connector which fits over the Euro threaded section so it's trapped by the fixing nut.
If this is not convenient you can fix your wire at the other end of the power cable. For this you need to open the welder case and follow this cable down inside. It will be connected to the rectifier which is one or more aluminium plates with other thick wires bolted to it. You must connect your thin wire to the same point as the thick cable. From what is said above it seems there is already spade terminals available that you can connect to. All you need is a suitable crimp on connector and push your wire on. If there isn't a spare terminal on your machine you can undo the bolt that's fixing the cable and connect to that. These bolts need to be tight as they carry the welding current so be sure it's well tightened.
Hope this may be of some help.

John

HelloI need to know if you could help me, I plan to install a new torch on my Telmig 180/2, I need if you can tell me what the correct connection for the European connector would be since I don't know anything about the subject and you mentioned that your modification worked.
Please contact san.roberto.1990@gmail.com
or whatsapp +56957179622. greetings from chile

 

[Nix2]

Here is the original wiring diagram.