Machine just clicking on middle power setting

[needaspirin]

I borrowed a SIP Migmate 130 from a friend to fix the chassis on my 1992 106. I have never used MIG before but can stick weld. The problem is when the middle power setting switch is set to MAX the machine just clicks when pressing the torch button. This means that I cannot use settings #3 & #6 as displayed on the diagram below (Thanks to BChild’s post),

I need setting#3 as lower settings do not penetrate and #4 blows holes through.

Any ideas why the clicking and how to fix it? My friend says the SIP is 15 years old and used very infrequently.

I am using CO2 and .6mm wire. My present overhead welding looks like a bunch of haemorrhoids

 

[R Kraft]

Unplug the welder ,Check the connections on the back of the switches, especially the center (max) one.
Robert

 

[malcolm]

Welcome. My guess, if a little obvious, is that the middle switch is broken

Could be a bad connection to the wires at the back, possibly dirty contacts, or I half recall someone with a SIP whose switches had filled up with sawdust. It'll be that switch though.

Cycling the switch backwards and forwards might clean off whatever is causing the trouble. Otherwise if you pull the side off the welder it should be possible to remove the switch, and they can be further dismantled for cleaning without breaking them.

 

[needaspirin]

Thanks Robert and Malcolm. I took off the side and found the clicking comes from a relay on the wire feed motor circuit. It also clicks when working normally. I noticed however that it was sparking a lot (except when middle switch set to MAX) so I prized off the cover and rubbed the contacts with fine emery.

I followed your advice and pulled off as many connectors as I could get at and worked them on and off a few times. I then operated all three switches quickly with both thumbs to give them a bit of a work-out.

When I powered up the set again I managed to get it to work with middle switch on MAX and did a few test welds. I’m beginning to like this machine!

I’ll probably dismantle the switches as you suggest Malcolm as it can’t do any harm.

Do you think a general spray with WD40 would be OK or maybe just on the switches?

Thanks again guys.

…Jim

 

[Rusty]

Buy a can of electrical switch cleaner ( prob Maplins ) and give em a blast with that.

 

[R Kraft]

Just spray some switch cleaner into the switches, WD40 turns into varnish and will cause more trouble.
Relay cleaner spray will melt plastic.
Robert