Hobart MIG, rapid clicking when trigger pulled.

[ObnoxiousFumes]

People with weldering experience, my Hobart Ironman 210 just started acting up out of the blue. I pull the trigger and it just clicks on and off rapidly.
I'm guessing it's a bad connection in the whip or trigger, what's the best way to troubleshoot this?

Thanks a bunch!
Jude

 

[Jswain]

Do you have a multimeter? Set it to ohms and unscrew the electrical connector for the mig gun from the machine. Touch both your leads from the multimeter to the 2 pins used in the connector. Nothing should happen til you pull the trigger on the gun, and it should go down to around .2 ohms or very low and stay there solid.

It if fluctuates then probably a shorted wire somewhere in the lead/handle. If it functions like usual then probably something in the machine.

If you do find the wire is intermittent somewhere in the lead you could run an two external wires taped to the lead from the switch to the connector

 

[ObnoxiousFumes]

Do you have a multimeter? Set it to ohms and unscrew the electrical connector for the mig gun from the machine. Touch both your leads from the multimeter to the 2 pins used in the connector. Nothing should happen til you pull the trigger on the gun, and it should go down to around .2 ohms or very low and stay there solid.

It if fluctuates then probably a shorted wire somewhere in the lead/handle. If it functions like usual then probably something in the machine.

If you do find the wire is intermittent somewhere in the lead you could run an two external wires taped to the lead from the switch to the connector

Thanks! I will try this tomorrow.

 

[Rockable]

If there is a relay in that circuit, it's probably gone bad.

 

[welder4956]

If there is a relay in that circuit, it's probably gone bad.

I was thinking the same thing, but could be the circuit board if the switch and relay check out OK.

 

[scooby074]

I'd start with the basics. Open the side cover and pull the trigger. Is the drive motor feeding? Remove the mig wire and try again.

 

[finn]

I think someone on the Weldingweb board had that problem, and it was a bad relay.

I recall that you could pay through the nose for a Hobart / Miller relay, or get a generic one for Pennie’s on the dollar.

Do a search on Weldingweb, or whatever it’s called.

 

[welder4956]

https://www.amazon.com/Miller-072817-Relay-120Vac-Flange/dp/B004RCDJ14?tag=atomicindus08-20

 

[welder4956]

Same one, generic:

20844-82

Relay, DPDT, 35A, 24VAC, Flange

www.galco.com

 

[ObnoxiousFumes]

Alright so the trigger wiring seems to be working. And I'm getting a steady 24volts to the coil on the relay so it looks like the relay is the issue.

https://www.amazon.com/Miller-072817-Relay-120Vac-Flange/dp/B004RCDJ14?tag=atomicindus08-20

This link didn't seem to work btw. Same as this fella though right?

 

[finn]

Same one, generic:

20844-82

Relay, DPDT, 35A, 24VAC, Flange

www.galco.com

Was it here or on the weldingweb site?

What you posted is exactly what I remembered.

Thanks!

 

[Wamsutta]

Alright so the trigger wiring seems to be working. And I'm getting a steady 24volts to the coil on the relay so it looks like the relay is the issue.

This link didn't seem to work btw. Same as this fella though right?

Being that it's see-thru, you could probably watch it flutter up and down real quick when you squeeze the gun trigger. It's not supposed to flutter. The contacts are supposed to close one single time with each pull of the trigger.

 

[ObnoxiousFumes]

Being that it's see-thru, you could probably watch it flutter up and down real quick when you squeeze the gun trigger. It's not supposed to flutter. The contacts are supposed to close one single time with each pull of the trigger.

Yes. I do sort of understand how a relay works