Bought a new to me Airco Dip/Stick 160 multiprocess welder

[Aeronca41]

The contactor terminal I can see in your picture looks pretty normal to me for an old machine, but maybe I can't see it well enough. What does bother me is the color of the associated spring-the other two are the usual color; that one looks like was really hot at some time. I agree with H80N-no good reason to be replacing the contactor yet. Need to find the short circuit first. Contactor may be OK.

Bob, that is some chain saw! Must have really big trees there in OH.

[aametalmaster]

offered him a trade of my husqvarna 562xp chainsaw and cash, I really hate to trade my saw even tho I don't use it much but it may come to that and I'll have to buy another down the road

That really sucks. Two things I like. Welders and chainsaws...Bob

[Hondacivic247]

[Hondacivic247]

I really hope to get this fixed as I wasn't really planing on buying another welder for some time, but if the caps don't solve it is spoke with the guy with the lincoln and offered him a trade of my husqvarna 562xp chainsaw and cash, I really hate to trade my saw even tho I don't use it much but it may come to that and I'll have to buy another down the road

[Hondacivic247]

[H80N]

I pulled the face plate of the contactor where the copper 3 prong thing is and the tabs inside look all sorts of arced over. I only noticed 1 arcing when I pressed the mig gun trigger but maybe all 3 were. So I'm thinking it will need a new contactor. I've searched online but haven't been able to find the exact one. It's a elmwood sensors 30 amp 240v . Lookingk down from the top it says 50-60c, 24? All the ones I've seen don't have this red side connection of sorts to connect the red and black wire to the motor for the wirearly feeder and the white wire to all the orange caps?

The contactor.....It is a magnetic electric motor starter... should be easy to source....."if need be"...

BUT...let's deal with one problem at a time though....

[Hondacivic247]

[Hondacivic247]

I pulled the face plate of the contactor where the copper 3 prong thing is and the tabs inside look all sorts of arced over. I only noticed 1 arcing when I pressed the mig gun trigger but maybe all 3 were. So I'm thinking it will need a new contactor. I've searched online but haven't been able to find the exact one. It's a elmwood sensors 30 amp 240v . Lookingk down from the top it says 50-60c, 24? All the ones I've seen don't have this red side connection of sorts to connect the red and black wire to the motor for the wirearly feeder and the white wire to all the orange caps?

[H80N]

At this point I would be tempted to take the caps out of the circuit...

and see if the wire drive motor perfomance returns to normal

the caps are in paralell anyway... and that would help to narrow things down...

you cannot weld without them... but it will give you an idea of a shorted cap if there is one

[Hondacivic247]

Is there anything you guys recommend that I check with my multimeter to help figure this mess out

[Hondacivic247]

Well I got home and I went through everything again with still no luck the contactorear is still clicking and sparking on the top and I have hardly any wire speed.

I really wish I noticed where all the sparks came from when it let go last night. I double checked all the capacitors and there in there correctly.

When I get the caps this week I'll try it out and hopefully they won't blow up and solve my issue. Otherwise I'll be looking for a new welder and either parting this out or something

[Hondacivic247]

Finding used mig welders 200+ amps are tough to find in my area specially the miller's and they always want more then I got to spend right now. The wire matic 250 isn't a big box store model.

[aametalmaster]

There's a machine I would really like it's a older Lincoln wire matic 250 for $850 with a tank and regulator

Does anyone really run a Lincoln Mig? I have worked in lots of shops over the last 40 years and Lincoln Migs were non existant. Granted people use them at home because they are cheap from the box stores. I got some customers last week in the LWS where I work and the kid asked where are all the Red machines. I said no one wants them so we don't stock them. He said I use one and I said because you bought it at Home Depot. I hope it all works for you either with this welder or another one...Bob

[Hondacivic247]

That's how that circuit runs from the small transformer to the rectifier bridge then to the cap and selector switch and the contactor has wires going to the wire feed motor along the copper windings in the high and low voltage transformer

[Hondacivic247]