A Shorted/Dead Welding Machine Repaired. Model: Apex ACR-180
A welding technician brought many welding machines for repair. This one was urgently needed so I started right away finding the fault in this machine. The technician explained that the machine comes on but does not weld because when I powered it on though a current limiter, the fan came on but the fins on the fan were all broken and based on that I figured right away, we are going to have blown parts inside.
I checked for voltages while the machine was on and as expected, it was dead, no reading whatsoever.
The technician explained that when he was welding, he heard the fan running he did know that the fins are broken therefore no cooling was being done inside.
Obviously, this machine was seen by another technician and he did not do a good job because of the mess that was done here. There are SMD diodes and resistors in this area but they were replaced with normal resistors and not with the same value.
Click here to access SS12 Datasheet
I started the repair here first before heading to replace the blown IGBT on the other side of the machine. I replaced the two resistors on both side and a diode.
The parts replaced here are SS14 diode, 220 and 5.1 ohm SMD resistors. The diode on the other side was ok so no replacement there.
Other the other side of the welding machine is a completely different story, the IGBT 60N60FDI was blown to pieces, the other IGBT with the same part number was no burnt like these but still shorted and needed replacement.
That is one of the replacements for the blown IGBT and of course adding a thermal paste is a must in this situation.
This is the other IGBT which is found on this heat sink; the bridge rectifier was tested and found ok so I did not replace that.
I cleaned the area, added a new IGBT on this side as well and I was about to test when the customer called me to ask if the machine is ready. I told him almost ready because I am about to install a new fan and then will test it out. He told me not to install the fan because he wants to do it himself. I explained that I will not take any responsibility if the parts are blown again and the customer agreed (thinking that he is saving money this way).
In order for me to test the machine, I installed a fan and powered it on using a current limiter device; this time I was able to read some voltage readings here and that is a very good sign.
My brother tested the machine out and it was up and running according to specs. I took the fan out, called the customer for pick up and when he came I made him sign a document that it is his responsibility not mine if the welding machine goes dead due to lack of cooling inside it.
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 Successfully Repaired A Dead Hover Board Charger
March 18, 2023 at 7:56 am
Stubborn customers are a part of our deals! An excellent work and you have resolved all issues to your best!
March 18, 2023 at 1:39 pm
Parasuraman: unfortunately there are a lot of them out there and somehow I have to protect myself. Some customers when I show them this document they change their mind about it and ask me to install a new fan others they do not care. have a blessed day and thanks for your comments.
Andrew F. Ali
March 18, 2023 at 10:11 am
Customers like these sometimes are very difficult to deal with but you did the right thing. Great work too!!!
March 18, 2023 at 1:39 pm
Andrew: thanks man. have a blessed day
Albert van Bemmelen
March 18, 2023 at 6:15 pm
Why this customer wanted you to fix and replace only the defect components in his machine but not the fan beats me? But it probably was because he already brought in so many dead machines that he wanted to save some money on all his repairs.
March 20, 2023 at 5:11 pm
Albert: the customer thinks that he was saving money by installing his own fan. the customer does not know the specs for such fan therefore the installation is going to be faulty resulting more damage to the machine. have a blessed day
March 18, 2023 at 10:18 pm
The customer probably had 2 or 3 dead machines with spare fans already sitting under his table lol.
March 20, 2023 at 5:14 pm
Jim: even if he has spare parts, every machine has different voltages, amp rating and rotations so it is not going to work up but ending up bring it back to me that is why I made him sign a paper for future protections. have a blessed day.
March 21, 2023 at 5:28 am
Waleed: You did the right thing in documenting the fact that there is no warranty.
As you said there are different fans with different, specs.There's no lack of ignorance anywhere in the world. If ignorance is bliss then why aren't there more happy people in the world? LOL
March 21, 2023 at 3:07 pm
Lynn: thanks man for your comments. totally agree. have a blessed day
March 22, 2023 at 11:16 am
Re "There's no lack of ignorance anywhere in the world. If ignorance is bliss then why aren't there more happy people in the world? LOL"
Ignorance of lies and deceptions (=most mainstream news and establishment decrees) is bliss because exposing yourself to that is self-propagandization.
Ignorance of truths is not, or only temporarily or rarely, bliss because it is ultimately self-defeating.
The FALSE mantra of “ignorance is bliss”, promoted in the latter sense, is a product of a fake sick culture that has indoctrinated its “dumbed down” (therefore TRULY ignorant, therefore easy to control) people with many such manipulative slogans.
You can find the proof that ignorance is hardly ever bliss (and if so only superficial temporary fake bliss), and how you get to buy into this lie (and other self-defeating lies), in the article “The 2 Married Pink Elephants In The Historical Room –The Holocaustal Covid-19 Coronavirus Madness: A Sociological Perspective & Historical Assessment Of The Covid “Phenomenon”” .... https://www.rolf-hefti.com/covid-19-coronavirus.html
““We’re all in this together” is a tribal maxim. Even there, it’s a con, because the tribal leaders use it to enforce loyalty and submission. ... The unity of compliance.” --- Jon Rappoport, Investigative Journalist
"Separate what you know from what you THINK you know." --- Unknown
March 22, 2023 at 6:49 pm
How clever of you to have him sign that waiver! Otherwise, he will bring it back to you and accuse you of not doing the job well.
March 23, 2023 at 4:02 pm
Joven: you are right and that is such a waiver is needed in our field of repair. I have encountered many issues that like before and I am not taking it any longer;it has to stop and that is the way to do it. have a blessed day
March 24, 2023 at 12:11 am
Good Job! Waleed,
I never give any option to the customers about quality. i just make the thing right by using good quality of parts which is needed for better performance of the equipment.
March 31, 2023 at 11:34 pm
good job .