Maypole turbo 125

nicho215 · Jan 13, 2008

Maypole 125 turbo got a rather old one of these need a wiring diagram as I am having trouble with the gas solinoid.
Problem is it is the gas solenoid on constantly as soon as main switch is turned on it goes off when machine is switched off. It is a 240v valve. Is there a way I could stop /start gas via the trigger from the tourch, I have recently done a euro torch upgrade and only now after reading info that came with the euro conversion kit which said gas should only start when trigger is pulled relised that it is not working how it should.
Nick

malcolm · Jan 13, 2008

You should have a 240V live (or possibly neutral - I'll need to check which way around the feeds are on this welder) direct to the circuit board from the main power switch. That goes straight into a relay or contactor where it is switched.

You want to wire the gas solonoid between the output of that contactor and the 240V neutral of the power switch.

You should be able to tell where the output of the contactor is by looking at the reverse of the board - the really thick soldery bits. Added some pics to show the contactor on a SIP circuit board.

Ignore the T1 and T2 - they might be the wrong way around on the photos)

rtbcomp · Jan 13, 2008

Aren't the gas solenoid and feed motor operated from the same contactor/relay? In that case I would have thought the feed motor would be running all the time.

Does the feed motor work from the trigger ok?

Does that model welder have a gas solenoid in the first place or a gas valve operated by the trigger directly?

PS Nick - I like your style - do the job then read the instructions :laughing:

welcome to the club :hug:

nicho215 · Jan 13, 2008

feed motor runs fine just solenoid isnt switched to the trigger
Nick

rtbcomp · Jan 13, 2008

nicho215 said:
feed motor runs fine just solenoid isnt switched to the trigger
Nick

That doesn't make sense, there are only two wires to the trigger, and if they switch the feed motor they must switch the gas solenoid.

Try disconnecting a wire from the solenoid and see if it still passes gas.

nicho215 · Jan 13, 2008

No gas when the wires are disconected from it if what you are saying is right can I link up directly with motor feed? If so would it be the one to the main switch or the one to the pcb? this model did always have a gas valve seperate from the torch.
Nick

rtbcomp · Jan 13, 2008

nicho215 said:
No gas when the wires are disconected from it if what you are saying is right can I link up directly with motor feed? If so would it be the one to the main switch or the one to the pcb? this model did always have a gas valve seperate from the torch.
Nick

Wouldn't like to say withoiut looking at the circuit.

The motor feed will be a variable voltage, so connecting the solenoid to it could

1) Interfere with the motor
2) The voltage on the solenoid will vary so it may not always call
3) The solenoid may operate from a different volatge to the motor circuit anyway.

Is there a marking on the solenoid which states the operating voltage?

malcolm · Jan 13, 2008

Is it really a 240V AC valve? My Portamig seems to have one like that. That is triggered from the output of the contactor.

I wonder if rtbcomp's advice might not be more suited to a DC valve. Motor side of the circuit is DC, so if you have a DC gas valve maybe that is a good spot.

Though I'm no expert in these matters by any means.

weldequip · Jan 13, 2008

Sounds like a faulty Solenoid valve to me, they do eventually fail. Got them in stock if you have no joy... just PM me

weldequip

rtbcomp · Jan 13, 2008

weldequip said:
Sounds like a faulty Solenoid valve to me, they do eventually fail. Got them in stock if you have no joy... just PM me
weldequip

But the gasflow stops when he disconnects it. :confused:

nicho215 · Jan 13, 2008

have included a pic of the circuit board
1.To main switch
2.To rectifier-Torch
3.To transformer
4.To torch
5.To feed motor
6.To transformer

Above all d.c
Below all A.c

7/8 To main switch
9. To neutral supply
10. piggybacked with 9
11. To main switch
12. To P.C.B to 10

weldequip · Jan 14, 2008

But the gasflow stops when he disconnects it.

It's stuck open then... it should open when the trigger is pressed & close when it's released. Thinking about it, it could be the torch trigger wires that have shorted as he says it opens as soon as the machine is turned on. Could also be a sticking Relay but I would also expect the wire feed to kick in aswell if it was a Relay problem.
weldequip

nicho215 · Jan 14, 2008

If I put a spdt relay between transformer i.e 26v dc to trigger on torch to power it then wire solanoid in line with it could that work?

nicho215 · Jan 15, 2008

Used 24vdc 30A relay in line with transformer and torch to get switching power put between neutraul feed to pcb and solinoid works ok. Due to delay in relay switching gas stops just after trigger released.
Thanks for all your help here no dout will be posting more problems again hopfully not too soon!
NICK

rtbcomp · Jan 15, 2008

nicho215 said:
....... Due to delay in relay switching gas stops just after trigger released.

That's a Good Thing. The extra gas will cool the weld before exposing it to the air, so reduce the chances of oxydisation

nicho215 said:
Thanks for all your help here no dout will be posting more problems again hopfully not too soon!

That's what we're here for!

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