SIP / Cosmo Mods

[skotl]

I'm using the same relay as you skotl. Looking at your photo of the relay, bottom left, blue pin 1, red pin 2. Bottom right blue pin 3, yellow with green stripe pin 4. Top left, brown pin 7. To me the base numbers printed on the base are laid out a bit weird, but I have never used eight pin relays before. If I start from the brown wire and work down the numbers are 7, 8, 2, 1. From top right, 6, 5, 4, 3.

OK - sorry - didn't realise you were referring to the same relay

I sold the SIP a while back so this is from just looking at pinouts. Short story is that I think you're spot on in your assumptions. This page shows the following pinouts:

From these, I think you're correct that 2 and 7 energise the relay when the trigger is pulled, the motor -ve feed comes from #1 and it is normally closed to ground on pin 4 and switches to +ve DC on pin 3


@mike 109444 - anything to add / correct?

 

[skotl]

By the way, sure you realise this but the diagram might suggest that the clamp, through the choke, is tied to the motor supply at pin 2. It is not - that's just an artefact of the drawing and these are two separate circuits.

 

[Marty J]

Thanks for getting back to skotl. Yes I realised that I needed to use a separate wire for the choke (big blue dot above my number 4) to -24v supply.

Just to confirm, looking at top of relay base pins are:
7 6
8 5
1 4
2 3

By the way this mod is running on my Cosmo 130. Thanks again.

 

[skotl]

Isn't the base stamped with the pin numbers?
Do you have access to a multimeter? Pretty straightforward to identify the base pinout with one of them

 

[Marty J]

Yes the base is stamped with the numbers as in post #183 and yes I did use a multimeter to help. I just wanted clarification on what I was doing.

The mod is working.

 

[Titus A Duxass]

Hello all,
I've been blessed with a Wolf 140 .
It's being used to rebuild my VW T3.

My brother who's an experienced welder says that the thing it's pants (he used other words), it won't keep stay during runs.

Is it likely that this welder suffers from the same problem that this mod cures?

He says it welds better in gasless mode I.e the wire feed is more consistent.

I've had a look inside and can see that it uses a large transformer for gas welding and a smaller transformer for gasless. The wire motor feed is driven by the large transformer.

Is it worth carrying out the transformer mod?

Thanks
Titus aus Leipzig

 

[Titus A Duxass]

Just a couple of photos of the internals.View media item 9661View media item 9660

 

[Marty J]

I am not familiar with the Wolf 140. Looking at the photo, it looks a lot cleaner than my Cosmo 130.

 

[Titus A Duxass]

After a bit of prodding about I can that the transformer mod probably will not work. The feed motor has it's own pcb (upper right in photo), the pcb has a transformer on it.

We did the brace mod and bought some better wire and it is now a useable welder.

 

[Steve Norfolk]

I would like to do this modification just not sure of the transformer output voltage is the 24 volts peak or rms, I have a transformer from a 13.8v 3A power supply the voltage measured right across the transformer is about 34v which would be the peak voltage is this likely to be suitable

 

[Cyruss]

Hi I`ve had my SIP 105Turbo for a number of years now, I have done the Metal Liner mod, The wire feed mod and now want to do the Wire feed transformer mod. (the welder seems to be getting worse each year, probably due to being stored in a shed) I am having trouble finding the Bridge Rectifier with the demise of Maplin and wondered if theres an alternative or specs of the bridge so I can source on through RS, CPC or Farnells (or even the bay of fleas)
Cheers

 

[bump]

This should see you right https://uk.rs-online.com/web/p/bridge-rectifiers/6296314/

 

[Cyruss]

Thanks

 

[Cyruss]

After a bit of prodding about I can that the transformer mod probably will not work. The feed motor has it's own pcb (upper right in photo), the pcb has a transformer on it.

We did the brace mod and bought some better wire and it is now a useable welder.

You pop up everywhere Titus, I need to be making my camper pretty now that it's running nicely. Thanks to your recommendation.

 

[Cyruss]

Sorry to keep posting.
Just installed my transformer and bridge mod today and had a go at welding some metal. The wire speed control is very hit and miss with the wire speed turned nearly all the way down.
I have to make a few alterations on the trim pot from what I've read.
The welds I've done have been quite nice but I've lost all confidence in my ability, I need lots of practice now but luckily I own a vw camper so there's plenty to weld

 

[skotl]

Sorry to keep posting.
Just installed my transformer and bridge mod today and had a go at welding some metal. The wire speed control is very hit and miss with the wire speed turned nearly all the way down.
I have to make a few alterations on the trim pot from what I've read.
The welds I've done have been quite nice but I've lost all confidence in my ability, I need lots of practice now but luckily I own a vw camper so there's plenty to weld

Yeah - it's worth replacing the trim pot on the circuit board, if you're comfortable de-soldering (or cutting!) components off boards. I forget the recommendation (it will be buried deep in this thread somewhere) but I found that replacing that made a big difference to controlability.

 

[ArnieS]

Hi, I am new on here so please excuse me for going over old ground, I am trying to do the wire feed modification on a SIP MIGMATE 130 TURBO and so far I have done the bracing mod, steel liner mod and the trim pot mod and am now onto the separate psu mod, I have a 240v to 24v psu which I have wired to the rear of the main on/off switch, I am using a double pole relay for the switching and that's where I am getting a bit lost, so far I have cut the black wire between cn1 and cn5 on the pcb and joined the positive + wire from the psu to the black wire that goes into the green block on the pcb, after this I am struggling, the relay pin arrangement is, looking from the front,
1 - 2 NC
3 - 4 NO
5 - 6 COMMON
7 - 8 POWER INPUT,
I am not very good a reading schematics so would be grateful if someone could please point me in the right direction as to where the other wire connections need to be.
Cheers.

 

[Sean]

this whole thread has got a bit out of hand, there are so many "No wait i did it like this" "No you need to do this relay and bleed down capacitor" etc

Id added the simple small transformer 24v, and bridge rectifier, no relays relays are just complicated. the Sip 105 welds really nice when using argon/co2 mix

follow "Bumps" instructions post 1 page 1 after page 5 it all starts getting complicated

 

[skotl]

Hi, I am new on here so please excuse me for going over old ground, I am trying to do the wire feed modification on a SIP MIGMATE 130 TURBO and so far I have done the bracing mod, steel liner mod and the trim pot mod and am now onto the separate psu mod, I have a 240v to 24v psu which I have wired to the rear of the main on/off switch, I am using a double pole relay for the switching and that's where I am getting a bit lost, so far I have cut the black wire between cn1 and cn5 on the pcb and joined the positive + wire from the psu to the black wire that goes into the green block on the pcb, after this I am struggling, the relay pin arrangement is, looking from the front,
1 - 2 NC
3 - 4 NO
5 - 6 COMMON
7 - 8 POWER INPUT,
I am not very good a reading schematics so would be grateful if someone could please point me in the right direction as to where the other wire connections need to be.
Cheers.

I'm a bit confused. As above, the pinout looks like this:

So:
1-3 NO#1
1-4 NC#1
8-6 NO#2
8-5 NC#2
2-7 Power (energise)

I gave an overview of how to wire everything together, what connects to what and why, over here if that helps

 

[ArnieS]

Many thanks for your replies, skotl, the configuration of the relay pinout you have shown is the same as mine but the numbers are different, I have also noticed I have the wrong information regarding which connections are no and nc, no wonder I'm confused, will have another go in the morning. Thanks again skotl and Sean.
Cheers.