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A Broken Fan Replacement On A Tiny Welding Machine. Model: Hugong

By Jestine Yong on May 28, 2022

This welding machine belongs to my brother next door. He is the one who usually tests the machines for me after the repair. It is his machine that needed service at this time.

The machine is functional but the fan inside broke.

You cannot do welding especially in a hot weather if the fan is broken or not providing enough cooling.

It is a very tiny welding machine but it is a powerful one and if you look at the fan it is about 4CM wide, 8×8 sizes and the amp rate on it is .45. These fans are very hard to find but I managed to get the same size but bigger amp ratings.

The fan runs on 24 DC volts and the amp rate as seen in the photo is 0.60 which a lot stronger than the original one and from experience it works just fine because I tried the same fan on the same brand welding machine and it was working like a charm.

My brother explained that his worker was welding and the machine somehow fell and a nail went through the fan vent and he started to hear a tearing noise. If you look closely to the fan you could see where the nail was hitting.

One of the fins of the fan broke and the machine started to vibrate. If you look closely where the arrow is, that is the broken fin that was glued back with super glue for while till I managed to get a replacement fan for this machine.

That is the final installation before connecting the main power to it. There are three wires connected to this fan but only red and black are soldered to the circuit board.

I put everything back and as always my brother tested it out and as expected, it worked like a charm and to that I could say

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 Dead LCD Projector Was Brought Back To Life

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Welding Machine Repaired

12 Comments

Paris Azis

May 28, 2022 at 10:55 pm

Well done Waleed! I can say that you were lucky with the replacement with a higher power blower... It happened to me to face the problem of the machine not working due to triggered protection against high(er) current draw, although the difference was at about 100mA more. I saw this protection triggered three times up to now, in three different welding machine repairs, which didn’t accept the stronger replacement, forcing me to find the exact replacements per each case! Note that the protection was not appearing immediately after powering on the devices...which put me in deep trouble the first time I had this experience...

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- Waleed Rishmawi
  
  May 30, 2022 at 6:06 pm
  
  Paris: thanks man. I never had such issue with replacing fans with higher amp rate. higher rate mean, stronger air flow going through and more cooling. I always add the positive and negative wire only, the sensor I do not connect therefore not triggering of anything in the machine. have a blessed day
  
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Parasuraman S

May 28, 2022 at 11:14 pm

Double satisfaction will be the result when we do some service to our relatives! Well done, dear friend!

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- Waleed Rishmawi
  
  May 30, 2022 at 6:07 pm
  
  Parasuraman: indeed my friend. have a blessed day
  
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Yogesh Panchal

May 28, 2022 at 11:53 pm

Good JOB! Waleed.

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- Waleed Rishmawi
  
  May 30, 2022 at 6:07 pm
  
  Yogesh: thanks man. have a blessed day
  
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Albert van Bemmelen

May 29, 2022 at 1:28 am

I suppose that the third wire was feedback from the hall effect tacho rpm sensor and not needed here.

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- Paris Azis
  
  May 29, 2022 at 2:58 pm
  
  That is true Albert and if it is not used, the fan runs in full speed.
  
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  - Waleed Rishmawi
    
    May 30, 2022 at 6:09 pm
    
    Paris: yes, that is true. thanks for your comments. have a blessed day
    
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- Waleed Rishmawi
  
  May 30, 2022 at 6:08 pm
  
  Albert: yes it is a sensor wire that I always take out. have a blessed day
  
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Lynn Blakely

May 30, 2022 at 6:46 am

Dear Waleed: Another job well done. The replies were appreciated also, we learned about the speed sensor in the fan.

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- Waleed Rishmawi
  
  May 30, 2022 at 6:10 pm
  
  Lynn: thanks man. have a blessed day
  
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