Shorted IGBT 60T65PES
A technician and a friend of mine called me and asked some questions about welding machine repairs. As this tech explained that the welding machine he was working on was completely dead and he needed some repair hints to get it fixed. I tried to explain as much as possible but at the end of our conversation, he decided to send it to me for repair.
It is a 200 amp welding machine that supposedly made in Germany but as you can see, it was completely dead and need some tender loving care.
As I took the top cover off and I could see that there is no way this machine was made in Germany as it was labeled on the front cover. It was a cheap China made welding machine that hardly cost anything to be made.
The two welding terminals connections are supposed to be made of copper but as you can see the white metal, that was not copper. Any ways, let the repair begins.
I checked the bridge rectifier and was not shorted and my next step was the IGBT’s on this welding machine.
Two screws were holing the heat sync to the board and as I took them off and soldered the pins of the IGBT, I was able to test the part and find out that both parts were shorted out and needed replacement. The part number: 60T65PES.
If you look to the multi meter reading, the IGBT was shorted on all its pins which mean I have to check all the component around it just to make sure nothing was burnt or shorted.
Sad to say, I did not have this part available in my shop but when I checked for the equivalent part for it, I found it was FGH60N60SMD which I have in the shop and that put a smile on my face.
I checked around these shorted parts for shorted components and it seems like nothing was shorted, open or out of the order, so I went ahead with the replacement of these two IGBT’s. I powered the welding machine on and to my surprise, the machine started to vibrate so I turned the machine off right away and checked for the cause of this vibrations.
One of the fins on this fan was broken so when the fan turns, it vibrates the whole machine so a replacement was due for this device.
I found the right fan replacement for this machine because if I replace the two IGBT’s and did not replace the fan, the IGBT’s will end up heating up and the welding machine will die again.
I turned the welding machine on and I was getting the right voltages. From past experience, getting the right voltages on the output of the machine does not mean the machine is up and running so I took it to my brother who is a welder and gave it a test. It was working like a charm.
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 repair articles in the link below: