Broke my mig welder

[mike 109444]

With the main transformer a basic check would be to look for signs of scorching or discolouring of the windings. It would be difficult to meter the windings as they will show as a short anyway. You could meter between the iron core (plates) of the transformer and each winding (at the switches) there should be NO continuity unless there is a shorting to frame of a winding. I think it is possible with all the work/parts done that there may be an issue with the connections to or of the diode pack.
1)If you disconnect the transformer from the diode pack and try the "plug off pcb" shorting of pins 1 and 5 again to see if it still trips. If it does not trip then reconnect diode pack connections
2) Disconnect the thick cable going from the diode pack to the torch (thick black that goes through to feed motor area/torch). Try again the "plug off pcb" shorting of pins 1 and 5. If it now does not trip then there is a short in that cable or where it connects to the motor area/torch (there should be an insulating bush or it connects on the plastic of the feed asy to prevent it shorting to the machine chassis or a short in the torch.
If in 1 above when you disconnected the diode pack from the transformer, it still tripped then there may be an issue with the correct connections to the power selection switches (HI/LO and 1,2,3) have you had to disconnect any of them? Failing that then could be you have a shorted main transformer . If you believe it is that then it would be worth removing it (after labeling leads) and examining it for signs of cooking.

 

[Paul Thomas]

OK checked the thick black cable to the torch and thats not shorting to the chassis. removed all transformer wire from the rectifier and shorted pins 1 & 5 , it did not trip fuse. I then attached the torch cable back onto the rectifier and tried this by bridge pins 1 & 5, I thought I could hear a slight hum but it did not trip the fuse. I then removed the torch cable from the rectifier and refitted the 2 main transformer cables back onto the tectifier, When I bridged 1 & 5 there was a spark at terminal 1 and the transformer was realy hummiming loud and vibrating the case but did not trip the fuse. All wire have back onto the correct terminals for both Hi & low power and the same for the rotary pwer switch

 

[mike 109444]

This sound like a fault with the rectifier. You did say in an earlier post that you fitted a brand new rectifier. I assume it was of same type and from a decent supplier?
If you were to disconnect the transformer from the rectifier, then meter between where the transformer would have connected to the rectifier and meter set to Ohms. Do you get a VERY low/short reading ? (you may get a bit of reading depending which way round your meter probes are due to the diodes but NOT a very low reading)
Meter between each of the plates and the chassis of machine again set to Ohms low/short ?
When you mounted the "new" rectifier, did you have to do any disassembling to it prior to fitting (brackets or such like)?
Where it mounts to the back panel, was there an insulating washer to stop the stud/pillar form shorting to the rectifier (I can see one at the front, under the nut).
It is also possible that the choke transformer has a short to it's frame. Can't see from pic if it is fried as switch is in way. The choke is simply a coil of wire wound round a transformer frame so there is ONLY one wire in (from the rectifier) and one OUT (to the work ground clamp socket)
With the humm you mentioned it would have probable blown the fuse eventually!
Hopefully someone else reading this with a 160 will post a pic of there machine from the side so we can check that all is wired as it should be. (would have to be a GAS only machine (not a GAS.NO GAS) cos that set up different and not one of the clarke range that uses a center tapped transformer cos again to different

 

[Paul Thomas]

I am needing to see pictures of the wire connections to the rectifier for a 160T if any body can help please.

 

[gaz1]

ive only got the clarke 150te

 

[Paul Thomas]

I believe they share the same rectifier and lay out inside so it would be intresting to see if you could please

 

[gaz1]

this one is already on the forums

http://www.mig-welding.co.uk/forum/attachments/20140224_155602-jpg.41810/

i will get some more pics of insides later today

 

[mike 109444]

I think you are right Gaz as comparing the two schematics, apart form the pcb numbers they look the same. I think this is why the question gets ask quite regularly when someone has seen and decided they need a clarke 150 or 160 and ask "what is the difference between them apart from price and ancillaries" ?

 

[gaz1]

even the pics look roughly the same together

 

[gaz1]

pics from my clarke 150te mig welder pics left at full size so you should be able too zoom in on them

 

[Paul Thomas]

OK I would like to say a big thanks to you guys, welder is now working. My fault as I had the rectifier wired wrong need to get a new roll of wire as its started to rust and causing the welds to be spatery

Info the wire to the torch need to go on the centre tab of the rectifier and the transformer to the outer tabs. Once again a bg thank you

 

[gaz1]

have you any pan foam scourers? as a clip will do it

something like this then your good to go

https://www.lawsonproducts.com/lawson/MIG-Welding-Wire-Cleaning-Pad-Red/CW5866.lp

 

[mike 109444]

But a big one of these
Result

 

[mechman]

pics from my clarke 150te mig welder pics left at full size so you should be able too zoom in on them

View attachment 109888 View attachment 109889 View attachment 109890 View attachment 109887

Is there a reason why your machine is so clean?

 

[gaz1]

because its still newish as ive hardly used it as i have 2 mig welders and i dont store it in a shed

 

[mechman]

because its still newish as ive hardly used it as i have 2 mig welders and i dont store it in a shed

AH.