A Simple Fix to Dead Welding Machine Brought It Back To Life
One of the regular customers brought me a dead welding machine for repair. He informed me that the machine was dropped while was on and end up not welding (completely dead) Once it was moved to my bench and opened up the machine I could see what was wrong with it.
There was no voltage readings on the main positive and negative terminals which suggest a problem either in the power supply not providing the right voltage for the machine to operate or something else wrong in the machine.
Let us find out.
Can you see the fault? One of the NTSC leg was loose off the board and that is an enough reason for the machine for the machine not to operate.
It was very clear that someone was in this machine because I could see fresh solder added to the board and I wonder why the tech was not able to get it fixed by just soldering it back to the board. Or is there another fault in this machine?
After soldering the loose pin of the NTSC part back to the board I checked for another fault and right away I could see this loosen screw on the output positive side of the welding machine.
From the look on that loosen screw I could see some dark spots which indicates spark were taking place here while welding,
Anyway I cleaned the area, tightened the loosen screw, checked for another fault in the machine but I could not find anything else.
There was one thing left to do and that was testing the machine for voltage output and as seen in the photo the output voltages on the main positive and negative terminals were outputting the right voltages.
I took it next door for my brother to check and confirm the repair and yes, the machine was up and running according to specs.
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 Welding Machine Powers On But Does Not Weld Repaired. Stayer: 200GE
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YOGESH PANCHAL
March 8, 2025 at 2:58 pm
Quick fix!Waleed
First time i see two NTC connected in series.
Waleed Rishmawi
March 10, 2025 at 11:16 pm
Yogesh: not a tough challenge of repair but it is ok to have an easy repair once in a while. Have a blessed day.
Albert van Bemmelen
March 8, 2025 at 7:15 pm
Indeed strange that someone failed to fix such an easy problem invain!
Waleed Rishmawi
March 10, 2025 at 11:18 pm
Albert: some techs too lazy to check around for repair, it took me a few minutes to find it. Have a blessed day
Parasuraman S
March 8, 2025 at 8:44 pm
Good fix, dear friend, the welders' man! Perhaps your brother can do away with his tool as you keep getting such machines and he can manage his work with these as testing procedures! (LOL)
Waleed Rishmawi
March 11, 2025 at 10:31 pm
Parasuraman: thanks. That is a very good idea but he has the CO2 welding machine in his shop so using these machines will be down grade for his quality of work. Have a blessed day
Mark J
March 9, 2025 at 4:45 am
Waleed good job on the repair. You are the welding machine expert.
Waleed Rishmawi
March 11, 2025 at 10:32 pm
Mark J: thank man. This one was easy to fix but thanks anyway. Have a blessed day
Imoudu
March 10, 2025 at 4:52 am
In the picture I can't see a loose nut but a lifted or burnt connector, pls try to use arrow or mark to identify the faults on board.Thanks for sharing.
Waleed Rishmawi
March 10, 2025 at 11:14 pm
Imoudu: the loose nut is the fault and it had an arrow pointed to it. Beneath that loose nut there is a connection that was loose so I soldered it and screwed down the nut. Have a good day.