Sealy 100

[barry gutteridge]

Hi everyone,I have a sealy 100 mig welder which the hose as gone I bought a new one but when I took off the old one it had one wire and the new one has two wires has anyone had the same trouble and fixed it I’m stuck please help me ,I have put some photos on to help

 

[mike 109444]

Barry can't make much of your pics but the diagram below is of a 150 which must use the same sort of torch as the switching is done from pin 1on pcb, through the switch (which was probable a sprung piece of brass that touched to the body of the gas valve). Then down the welding power line (braided outer) and back to the rectifier (the connection on the ally plates) GET THE CORRECT ONE when you connect yours up !
The other pics (not the best pic I know ) shows at the top your original set up and the bottom shows the extra wire (blue in pic) going down to rectifier.
I assume your machine is NOT a Gas/NO gas machine as this may not work on that.
And welcome BTW

 

[mike 109444]

ps there is an easier way but I am not sure how much room there is in your new torch handle.
You would need to connect the torch at welder end as per original torch, then the extra wire can be ignored (taped up)
Now at the torch end disconnect the extra wire from the switch and make up a short wire to connect onto the switch where the extra wire went. This short wire should connect to the weld power/brass block.
pic is of a Clarke torch (a single wire one!) just to show where.

 

[barry gutteridge]

Hi ,Mike that sounds right to me I think you have cracked it I will try tomorrow and get some more photos of the old gun inside and the new gun inside your a great help I will get back to you thank you very much