Mars 200 mig mars electrical diagram help please

[GavinB]

Hi All,

Im hoping someone can help with a wiring diagram for pcb, voltageposition/cam switch and contactor for Mars 200 mig mag.

I am struggling to find any useful information for it online....

It seems to have all the equipment but not the electrical wiring.

So maybe someone who is a lot smarter than me on here (and there seems to be a lot of you) are able to try and help me out so I can get started on my project list. Thanks


GavinB

 

[eddie49]

Hello Gavin, and welcome to the Forum !
The Mars range of welders seems to be an Aus/NZ speciality. I've found some indications they could be re-badged Telwins ( Italian ).
It appears to be a basic step-switched transformer machine, with 8 power ranges.
When you say:

It seems to have all the equipment but not the electrical wiring

do you mean someone has stripped all the wires out, leaving just the hardware components ? !! If so, that will be a tough project.

 

[GavinB]

Hi Eddie,

Thanks for the welcome and reply!
Yes I have seen all the welders that appear very similar, but I’m just not 100% sure.

I got the mig very cheap and I’m not looking to weld anything too adventurous with it, just a few small projects that I have been waiting to get into.

Nearly all of the wiring is gone and the few that are there I am not too confident that they are correct!

I am hoping that I can piece it back together and repair replace anything that is damaged ( if anything at all)

Guess I’m just looking for some place to start investigating/checking??

Do you think I should look at a model of Telwin welders ( or a different 1)and start piecing electricals together?? If so which one?

Thanks again Eddie

 

[wacky7791]

seen these on ebay they are a pretty cheap machine to start with, maybe put some pictures up of its internal issues and PCB's? there are some very knowledgeable electronics folk on this site with some images of its actual problems they may be able to help with or without wiring diagrams? at the price I'd say they were Chinese.

 

[eddie49]

I would start at the main transformer.
A visual inspection to check where the wires enter and leave the primary coil, plus an Ohmmeter, may be enough to find one end of the primary winding. If the other ends are 8 taps, with progressively-increasing resistance, then there may be a good chance of getting this machine working.
( However, we're talking very low resistance - a couple of Ohms, with tiny increases in resistance for each step. A typical DVM with the lowest Ohms range of 0 - 200 may not be precise enough. )
If that is how the transformer looks, you can maybe confirm this by looking at the power range switch ( cam switch ). It should be 1-pole, 8-way.

Anything else, such as multiple windings and start/end tappings and windings getting switched in and out of the primary circuit will be a nightmare without a diagram, or a good machine to compare with, so you may as well give up.

After this section, the trigger switch, the wirefeed motor, the gas valve, even the PCB, will be pretty easy to decipher and reverse-engineer.

 

[GavinB]

Thanks eddie49 and Wacky7791 for your help so far.

Here are some pictures of internals, there are seven wires coming out of transformer.

I have found various companies in China, Brazil, New Zealand etc who make and sell these machines but little or no pictures or information on internal wiring. I found a secondhand one online and asked for some pictures but they didn’t really help.

Also I found a manual online (but in another language I think it’s Portuguese???)For the first two power settings it says something about “unstable”

Does anyone know what that means???

I am more than happy to tinker with it to try and get it going/fixed with some guidance, and at same time improving the small amount of mig knowledge that I have hopefully.

Here are pictures of my transformer and one side of pcb. I think off memory there are 7 wires that appear out of it (4 single and 3 doubles)


And here are pictures I asked
for of welder for sale, but didn’t really help too much.




Tomorrow I will get my multimeter and see what I can learn from the transfer windings.

Thanks again for your help so far

 

[wacky7791]

that (Portuguese?) text picture is selector position and output current but is for mig 130 and mars 205 models.

what exactly is the problem with yours? doesn't turn on? , doesn't create an arc?

 

[GavinB]

that (Portuguese?) text picture is selector position and output current but is for mig 130 and mars 205 models.

what exactly is the problem with yours? doesn't turn on? , doesn't create an arc?

There are quite a few wires either missing or not connected, so I would like to try and wire it up and see if it works or try and repair it.

Yes the text is for Mars 130 & 205 models, but what caught my eye was for the first 2 heat settings it says something about the power being “unstable”???is that normal for most migs ????

Unfortunately I ran out of time today to try and check the resistance in the primary coil wires.

 

[GavinB]

Here is link to another page

https://www.shiweld.com/product/mars-160-180-200-migmag-welding/

 

[wacky7791]

can't find anything on these machines diagram wise and the pictures above don't really show what is or isn't connected, reckon you need another of the same mig to copy off I'm afraid.

whereabouts in Australia are you?

 

[GavinB]

A couple of hours west of Brisbane.

 

[GavinB]

Look what I have now!!! Is this going to be enough to help me check the wiring for the mig even though there is not a diagram for power selection?

 

[Screw]

 

[Nix2]

@Screw...
the Mars diagram above is quite different, but the post is old, from 2020...