A Simple Fix To An Abused Welding Machine. Model: Zika
Zika welding machines are considered the top of the line when it comes to welding yet I get them in the shop for repair simply they were abused by the technicians. Take a look.
The front plastic is gone, the body is really dirty and started to get rusty and a power cable was added to it on the wrong side of the machine.
The power cable is exposed and could endanger the life of the welding technician.
The machine is totally dead and the customer wanted it repaired as soon as possible.
If you look the right side of the photo, you would see the added power cable that is connected directly to the main power board and that is not good at all.
I started to check voltages reading at the main board but before that, I connected a new power cable through the power switch to the main board and of course connected through my current limiter device and powered on the device. The machine did not come on but I was glad it was not shorted out.
If you look to the photo, you would see a bad soldering job on the main power board. Someone has been in this machine and of course made it worse.
Here is a closer look of what has been done here to one of the main capacitors located on the main power board.
I found a lot of cold soldering joints on the main power board and some that has crack in the solder. I re soldered all these joints on board and hoped for the best.
I found a lot of cold soldering joints on the main board and that is very close to the main brain of the machine. In other words, if the main brain did not get the right voltages here it will not send a command signal to the relay to click to make the machine come on. So I added fresh solder to almost every joint there and checked component on that board and made sure there was nothing faulty there.
The machine came on (sorry I forgot to take a photo of that). I added a new power cable to the machine which made it safe to operate.
The customer came and looked at his machine and he loved what he saw. I do not like this kind of repairs since it was not a challenge but simply cosmetics repair and paying attentions to safety and tiny details but the customer liked it and that what counts.
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 Security Camera Was Brought Back To Life