Sureweld Monomig switch

[timokenn]

Hi folks,
It's a bit of a long shot but here goes.
I've got a really old Sureweld Monomig 201 but it's been a damn good welder over the years.
Recently, the 6 position power switch went faulty and only worked on 2 settings (2 and 6..practically useless.)

I've taken the switch out, it has 15 connectors, all of the corresponding wires seem to disappear into the transformer.

I've rang around local welder supplies but no luck..I've even been on to Sureweld who now no longer keep spares for that model...so my only hope lies with fellow enthusiasts who might have a switch lying around.

I've enclosed some pictures of the switch.
I'm a bit lost and stuck without it so if anyone can help me, I'd be very grateful.
Looking forward to any and all help.

 

[mike 109444]

Timokenn Read this link and then contact Rosepuds ?
http://www.mig-welding.co.uk/forum/showthread.php?t=38843&highlight=switch
Failing that ebay ang the Hong kong sellers have similar (will have to wait for delivery, 1-2 weeks)

 

[mike 109444]

PS welcome BTW and glad to see you labeled the connections !!

http://www.mig-welding.co.uk/forum/showthread.php?t=35966&highlight=switch
Note the ori switch does have the connections 1, 2 ,3 in sequence but even though it looks wrong the 4, 5, 6 do go 4, 6, 5

 

[timokenn]

Thanks for the info and links, Mike.
I actually spoke to 'Rosepuds' from York a week or so ago. He can supply a 6 position switch but with completely different connections so I'd be at a loss as to how to wire it up. He seems like a very helpful guy though so there may be a way. The ebay route would be fine except I haven't found the same switch. Although waiting a week or so wouldn't be an issue for the right one.

 

[mike 109444]

Its not that difficult to work out a new switch to replace your existing one If as you have done the cables are marked.
The one I got from Hong Kong was very different to my orignal (which looks same as yours) The Hong Kong one is a lot simpler to work out and as I had added some extra turns to my transformer when I rewound it, it was 6 now 11 which is just as well cos the 12 position switch from HK was infact an 11 position!! noted it's still being advertised as 12 position.
Cheep as chips
http://www.ebay.co.uk/itm/Welding-M...al_Components_Supplies_ET&hash=item460acfea1c

 

[mike 109444]

ps did look through his eshop but there is not a 6 position one suited to what you want. Note 6poles is not same as 6 positions.

 

[timokenn]

Hi Mike,
I wouldn't have a clue where to start wiring a different switch. Especially if it had a different number of pins!!
Mine's a 15 pin switch, which does seem excessive!

 

[mike 109444]

It may have 15 pins but will (on a 6 power welder) should only use 6 + 1. The 1 will be the incoming and the 6 will be the 1 of the 6 selected. If you look at your ori switch it has bridging link that add complication to the look of the switch.
Am I correct ref the number of wires going to the switch (6 + 1) total 7

 

[timokenn]

No, there are 15 wires going to the switch. All seem to come from the transformer.

 

[mike 109444]

So are there 15 spade connectors that go onto the switch? or is it that on some of the spade connectors you have what looks like two wires (which then go back to transformer)? Which you count as two?

 

[timokenn]

There are 15 individual spade connectors going to 15 separate connectors on the switch.

 

[mike 109444]

How many go to the transformer (count the ones that are two wires in one spade as 1) Are there 7 ?

 

[timokenn]

As far as I can tell, Mike, all 15 seem to go into the transformer

 

[mike 109444]

Are any of the wires coming/going to the transformer doubled up in a spade connector as per my pic?

 

[timokenn]

Hi Mike, sorry for the delay, I just nipped out to the garage to double check. No, all the wires are single wire spade connectors.

 

[mike 109444]

Tim could be you connections to the transformer is as per option 2 rarther than option 1. In option 2 the wire coming out of the transformer has a spade connector and then returns via a second spade connector. The connection on the switch forms the link back to the transformer. If you look at say number 1 on the switch you will see that there are 2 male spade connection to it but they are just one connection as it is a "U" shape.
The pic is only of a 4 power switching but would be same for 6 as per yours.

 

[timokenn]

Hi Mike,

Given that all the connectors are single wires, I'd say it was more likely to be option 2. Although I've no way of knowing where the wires go to once they disappear into the transformer.

 

[mike 109444]

It kinda does not matter where they go once they go into transformer, so long as you have them labled ! When you were removing and labling did you remove say the wires from the switch connector number 1 (two wires) and lable them 1 and 2 Then same for switch connector 2 (two wires) and labled 3 and 4 and so on through all 6 switch connectors. If so that would have given you 11 as the last one (on number 6 connector) would have been a single wire.
You would then have a single starting (call it the common) which would have gone to the S/L2 connector giving 11 + 1 +12 wires going to transformer.
So I am not sure where you are finding 15? wires to switch from. Are you sure on that quantity. Your ori photo of the labled wires does not show clearly the lables due to camera flash?
It might be that they have used some of the switch connectors to feed something else. Did note that you r machine has the red socket (spot welder connection) on the frount. We were recently trying to figure how this might have been connected internally but the chap with the machine in question did not own the welder so could not take apart to photo back of socket so never did get to bottom of how this was wired in. It would probley need to take a feed from transformer?
I don't think you should have a problem getting a switch as both my welders used same type switch, One VERY old clarke 120 and a Boramig. Both of these welders are of Italian build (befor the Chinees invasion! roughly pre 90's) So I recon that any welder of this era with a 6 position rotary switch will be same. When you spoke to Rosepud did you say your switch had 15 connections going to it cos that may have caused some of the confusion. will stick some pics up of the switches.

 

[mike 109444]

This link is for the company that made the switch in my old clerke (sticker was still on it). The type of switch i think is refered to as a cam switch
http://www.bremasersce.com/

 

[mike 109444]

Pics of various welder switches
Top left My Clarke
Top Right Old SIP
Next down Sealey
Last My Boramig.
You might just be able to make out on the Clarke and Bora the doubling up of the wires going to the terminals.