Post some pics of your relay if you've got it, and we can try to help you out.
Cool - the spec sheet here confirms your pinout - apologies for the confusion!
Dont suppose you still have the cosmo welder. I discovered the voltages out of the torch on my cosmo 130 are way too high - leading me to suspect the wires from the transformer have been relocated onto 3 switches incorrectly. I have a question on the SIp/Cosmo forum asking if anyone could look at the location of the wires out of the transfromer and where they go. Secondly asking if someone could measure the voltages o n each of the switch settings. Thanks for any help you could give.I did it
Well I did it but I haven't had a chance to try it out yet.
Things I did wrong
1) I connected up the 240v side of the transformer an tested the outputs ... nothing. I then tested the connections and thought Mr Bump had got it wrong or my Cosmo was wired differently. In fact if you are testing the output from the transformer you need to push the torch trigger !! The Live and Neutral in the pictures are only live when the button is pushed. If you then switch to the permanent live (i.e. the bottom two spade connectors then when you switch on having finished the wire feed will run straight away whether or not you have pushed the trigger.
2)When testing the low voltage side of the transformer remember to set you multimeter to AC volts!!
3) I sourced my transformer from RS and bought the Chassis Mounting Transformer Part 805-271 (100VA 2x12V 4.17A) it was £12.90. In retrospect I think I should have bought Part 805-316 (100VA 2x24V 2.08A) again only £12.90. Looking at the specs with the 2x12V one in series the specs look the same as using a single secondary of the 2x24V .. I don't know and hope someone who knows a little more can comment.
The only other differences between my attempt is that I pop-riveted the transformer to the base of the unit (int true far-east lo-cost stylee) and I routed the cables via the existing grommet. In the pictures you will see I have yet to secure the rectifier.
Before switching the motor feed I checked the DC volts to the wire feed motor on max and min, they appeared to be about 5.5VDC to 24VDC. Switching to the new transformer I found I had to adjust the small trimpot. I ended up taking it down to about 3VDC on the lowest setting. Be aware that the trimpot is very sensitive at the lower end of the scale.
