How To Fix A Dead Short Welding Machine
A welding technician brought his dead welding machine for repair. It was completely dead; no life whatsoever.
The first step was to test the main power coming to the machine so I disconnected the phase and neutral wires
and I could see voltage reading registered on my multi meter and that is good.
I needed to find out where the short is coming from and to do that I disconnected the power cable that provides 220 volts to the upper board from the main power supply.
With the cables disconnected from the main board I powered up the device through a current limiter and guess what?
The main power supply is shorted out and that is where my focus is set at this time.
The first thing I could think of right now is the bridge rectifiers; there are usually two of them.
Once there were disconnected of the board and tested I found one shorted out, check it out
I checked them while there were in the machine and found out this was shorted out so it was taken out of the machine for conformation.
Yes, the bridge rectifier was tested and confirmed that it was shorted out and needed a replacement.
I found the exact part number in the shop and right away I de soldered all wires of the faulty part soldering them back on the new part adding heat tube to the pins, heated out and soon enough it was ready to be installed back on board for testing.
This is the final outcome of the repaired bridge rectifier. I installed and through a current limiter again tested the device and as expected…
The current limiter lid for a few seconds till all the capacitors were charged up then it went dim indicating a healthy working welding machine. Of course I took it next door for my brother to check and as expected it worked just fine.
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 Samsung TV with No Backlight Repaired and Maintained
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Yogesh Panchal
March 29, 2025 at 4:51 pm
Good Quick Fix! Waleed
Waleed Rishmawi
March 30, 2025 at 10:46 pm
Yogesh: not that quick, getting to the shorted part and putting the new one in was the hassle. Have a blessed day.
Parasuraman S
March 29, 2025 at 4:53 pm
Taking the machine next door for evaluation is the extra facility you enjoy every time! I envy you! (LOL) Many thanks for sharing another welding story!
Waleed Rishmawi
March 30, 2025 at 10:49 pm
Parasuraman: you are most welcome. Taking it next door for testing is really fun and now my brother is teaching me the welding techniques so I can test the machine myself. Have a blessed day
Mick Mason
March 29, 2025 at 5:03 pm
Great repair Waleed. You seem to be the 'go to' man for welder repairs in your area ! You make it seem so easy ! Well done again !
Mick M, UK
Waleed Rishmawi
March 30, 2025 at 10:53 pm
Mick: thanks man. I am the only tech in the area that deals with welding machine repairs. Other shops they deal with tv repairs only. Sometimes I get easy repairs and sometimes not that easy. Have a blessed day.
Albert van Bemmelen
March 29, 2025 at 5:22 pm
Nice to see that they made it easy to replace bad rectifiers by giving them 4 wires connected to a plug on connector.
Waleed Rishmawi
March 30, 2025 at 10:42 pm
Albert: they do not come with wires I took the old ones off the shorted one and soldered them to the new one. Have a blessed day
Mark J
March 30, 2025 at 3:12 am
Waleed I like your current limiter setup. Good job on the repair.
Waleed Rishmawi
March 30, 2025 at 10:44 pm
Mark J: thanks man. It is hand made and very helpful device for the repair. Have a blessed day
Imoudu
March 31, 2025 at 5:06 am
An expert on any field of endeavour will not waste too much time on the job,thanks for sharing.
Waleed Rishmawi
April 1, 2025 at 12:01 am
Imoudu: you are most welcome. We only use the time wisely to get things done. I appreciate your comments; have a blessed day