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Could Hear Relay Click Sound But No Continuity…..

By on November 10, 2021
relay problem in welding machine









I got a call from my brother saying that his welding machine keeps going into shut down and does not know the cause of it. He explained that it comes on and he start to weld but suddenly even with the power switch is on, it goes into shut down.

welding machine relay faulty

It is a used welding machine and so far it has been serving him well but today it needed some tender loving care service so here it goes.

He brought it to my shop and when I powered it on, the relay kicked in which means the main brain of the machine is work just fine and then I could hear another click then the machine shuts down. I think I know where the problem is, but let us investigate to make sure.

how to fix welding machine

As I took the power supply out of the welding machine; my focus was set on the relay because the sound of the clicking did not sound good at all.

bad relay

I soldered off board and I could see the broken side of it.

Could it be a dust issue? My brother uses his machine in many dusty areas and I am almost sure dust got into the relay and messed it up.

testing relay

I applied 24 volts to the coil of the relay and it could hear a click but when test continuity between the two pins, continuity was no solid.

Since it was already broken, I decided to experiment with it and see the actual fault. I broke the plastic off and right away I could see a lot of dust. The pins of the relay were black but the worst; the pins were bent and do not make a clean contact very often.

bad relay

I have plenty of these relays in the shop and right away I replaced the bad one with a good one.

how to test welding machine output dc

As I put the machine back together and took it to my brother for testing, the machine stayed one and the welding was according to specifications.

My brother is a welder and he usually test the welding machines that I repair for customers but this time he was testing his own machine and he was glad it was up and running.

Mission Accomplished.


This article was prepared for you by Waleed Rishmawi, one of our ‘Master Authors’ and currently working in the Bethlehem area of Palestine repairing electrical and electronic equipment.

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Note: You can check his previous article on Bed Recliner Board Repair




  1. Parasuraman S

    November 10, 2021 at 5:48 pm

    The welding and mending team go very well together! Well done!

    • Waleed Rishmawi

      November 10, 2021 at 6:08 pm

      Parasuraman: indeed. Have a blessed day

  2. Albert van Bemmelen

    November 10, 2021 at 10:21 pm

    You always have almost every spare part in stock and I wouldn't wonder if you even had completely new welding machines in stock too? (lol).

    • Waleed Rishmawi

      November 11, 2021 at 4:40 pm

      Albert: yes, almost but not fully to build a welding have a good and blessed day

  3. Yogesh Panchal

    November 11, 2021 at 3:47 pm

    Well done! Another Machine revived,Waleed

    • Waleed Rishmawi

      November 13, 2021 at 4:05 pm

      Yogesh: thanks man. have a blessed day


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