Hi, terminal 2 has wire 11 blue neutral to it.Looking at the cam switch jumpers, between pins 2,6,10, and 14, are there any other wires joined to any of those terminals?
My post #46 probably a bit of over kill but list's what I've done any suggestions of errors etc greatly appreciated.Looking at the cam switch jumpers, between pins 2,6,10, and 14, are there any other wires joined to any of those terminals?
The datasheet for the CMP8 relay:Call me old-fashioned, but I'd be expecting to see something connected to that large power relay at left of the PCB...
Hi, thanks for all your effortI've been over the wiring I posted and looked at the circuit a bit more and it should work, I was going to suggest swapping L & N and also swapping what was pin 12 and pin 10 over because I thought that they were wrong but they aren't.
Firstly, does the power light come on ?
The thermal overload light shouldn't come on but the power light should.
There are TWO relays on the PCB, I think what you are hearing is the smaller relay clicking in and the big relay isn't.
Can you set your meter to the highest AC volts setting and measure the voltage across the pin labelled CN4 on the PCB and the live pin. It should be mains voltage until you press the trigger when it will go to 0V.
This sounds difficult but you can measure it at the relay across the COM. and N.O. spade terminals which may be easier,
If the voltage doesn't drop to 0, it means the relay isn't energising probably because the voltage is too low.
Try setting the welder to setting 1, 2, 3, 4 and press the triggger on each of the settings and see if the relay energises on any of them.
If it does energise on one of the settings, move the wire that is on terminal 8 to to one of terminal 2,6,10 or 14.
If it doesn't energise at all let me know and I'll start my second pipe.
D
The datasheet for the CMP8 relay:
shows that the spade tags on the top are described as "Quick Connection", but they are duplicated by solder pins underneath for PCB mounting.
Of course it quickly becomes obvious (as posted by others earlier) that the 'new' switch won't swap in directly.
Studying the truth chart suggests that one contact in each pair (per position) could be linked together as a common live for the PCB transformer, the neutral could then be made permanent which isn't the end of the world. Althernatively (as suggested) fit a double-pole rocker switch to the front panel, or go the whole hog and put a mains contactor in
So you could link all the even numbers 2-16, connect to incoming Live.
Link 3-7-11-15 and take to the PCB as the Live for the supply transformer.
1, 5, 9 and 13 go to the transformer taps in order of increasing output (corresponding to 2, 4, 6, 8 on the original switch).
Take the incoming Neutral direct to the PCB as its supply and the N for the main relay to switch.
Not the last word in safety but as long as the cover's on, there's not much scope for anything to go wrong.
Oh OK then, here's a fagCAD
View attachment 366316
If you want to go that route, it's quite simple as it's not really much different from what you have.
You will need a chock bar connector or some other terminal block. Sort this out first, you will need to connect the incoming mains neutral to the wires that were originally labelled 10. They can probably all have their ends cut off and crimped together or connected via a terminal post or choc-bar connector etc or replace the fork terminal with eyelet terminals and connect them with a screw and then really insulate them with lots of electricians tape if you're feeling really bodgy
1) Remove mains Neutral from the switch.
2) Add another link to join terminals 14 and 16 (this connects all even pins to live).
3) Remove what was originally wires 12 and wires 10 from the switch.
4) Connect what was wires 12 to terminals 3,7,11,15
5) Connect what was wires 10 to the Neutral wire disconnected in step 1.
& that's it.
D
Cheers D
Just got back from Birmingham, M6 nightmare.
Will have a look what I have available tomorrow to carry out your kindly added steps.
Will be in touch with update.
Thank you so much.