A Welding Machine Powers On But Does Not Weld Repaired. Stayer: 200GE
A welding machine that stopped welding was brought to my shop for repair. The technician said it suddenly stopped working and the yellow LED light came on. Usually when the yellow light come on during the welding process, is a warning sign of overheating or a short on inside; the machine is protecting itself from further damage.
It is a heavy duty one and they do not make like them anymore unfortunately so I went ahead with finding the fault and with the repair.
As I mentioned before, when the warning light come on it is either overheating issue or shorted parts. I looked at the fan and it was running just fine and the cooling was enough so I focused on the IGBT/Mosfets situation to see if they are shorted or not.
I found these IGBT shorted out, 60T65PES and I found only two shorted. In a situation like this when two only shorted I usually replace all four and that is what the customer agreed to.
Click here to access the above IGBT Datasheet
The moment I took the shorted IGBT’s out the yellow warning sign disappeared which is an indication that the short is gone and I can proceed with the replacement of the parts.
All IGBT’s were replaced, thermal paste added and then tested.
As seen, there are voltage readings on the negative and the positive terminals of the machine and that is an indication that all is well and it is not time to test it out next door.
Testing confirmed by my brother and I called the customer as always for pick up. I let the customer test it out before leaving that shop and that is a new procedures that I started in the shop giving the customer the feel the change and to confirm himself that is all well.
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 A Shorted Computer Monitor Repaired and Maintained
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Parasuraman S
December 28, 2024 at 5:21 pm
I agree with you! All four mosfets should be replaced to have even current! Good job there, dear friend and thanks for sharing!
Albert van Bemmelen
December 29, 2024 at 1:39 am
Knowing that the moment all shorting IGBT’s are out of the circuit in the Potenza 200GE and the yellow warning sign disappears, is a good way to be certain that replacing those IGBT's will be successful when we ever have to replace those semiconductors too!
Ecellent repair tip!
Imoudu.O
December 29, 2024 at 3:42 am
Master of wielding machine, carry on.
Mark J
December 29, 2024 at 4:50 am
Waleed another well done Welding Machine repair. Thanks for sharing.