Shorted IGBT In Welding Machine Repaired. Model: ACR250
A friend of mine who has a repair shop in town called me about this welding machine. He said it belongs to his friend and he wanted it to get fixed. My techi friend does not repair welding machines therefore he asked me to help him out in this matter.
I powered it through my current limiter and as seen, it has no sign of life whatsoever.
The machine was already opened by my friend and by looking at it I did not like what I saw.
The way the cables are connected together inside the machine is not my way of doing things but anyways, the repair will continue if I like what I see or not.
From experience, this kind of machines go dead the moment the IGBT’s are shorted out and that is where my checking started. As expected, four of these IGBT are shorted and needed replacement.
The part number on these parts is FGA6560WDF which is 60 amps and 650 volts ratings and sad to say I did not have these parts available in my shop so I contacted my friend and explained the situation. The customer was willing to wait for the parts to arrive because he has other welding machines in this shop therefore he is not in a hurry.
Click here to view FGA6560WDF Datasheet
I placed the order and hopefully I will get this in a two weeks to one month but at the mean time I did some checking around these shorted IGBT’s to make all is well before installing the new parts and end up with a disappointment.
I took a look at the fan and I did not like what I saw. It is not the original fan and it is too tiny to provide the right cooling for this welding machine. Of course I gave my recommendation to my friend but I got an answer back that the customer is content with this fan and he does not want to replace it at this time.
The parts came and the replacement was done. I was about to power on the machine through a current limiter when I saw these wires.
The color code on these wires is different and therefore I cannot tell which one is the ground because usually in my country the ground is usually the green but in this case it was different. Take a look
In this case, the white was the ground wire and I was so glad I checked because if I did not I might end up with a boom in my shop and I do not like booms..LOL
Power plug was installed, powered on the device and the machine is alive and I was getting the right voltages here. I called my friend and he was happy to hear the good news so he drove to my shop for pick up.
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 How To Fix A Remax Welding Machine
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19 Comments
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Imran
February 18, 2023 at 8:29 am
Good repair work ☺️
Waleed Rishmawi
February 18, 2023 at 3:33 pm
Imran: thanks man, have a blessed day
Charles Karonga
February 18, 2023 at 9:41 am
Greetings
Well done and thank you for sharing as usual.
Through you step by step explanations regarding these welding machines,I too became confident to repair them and was successful with 15 machines so far all credit goes to your well explained articles.
Its like you are holding welding machines toddlers with a firm right hand.
Keep sharing your articles and Thanks to Jestine Yong and all my Techie Friends who add value to this forum.
Regards
Waleed Rishmawi
February 18, 2023 at 3:34 pm
Charles: you are most welcome.
very happy to know that. keep up the good work and have a blessed day
Parasuraman S
February 18, 2023 at 9:54 am
That was a clever and alert find about the wires! Well done!
Waleed Rishmawi
February 18, 2023 at 3:35 pm
Parasuraman: thanks man. have a blessed day my friend.
Andrew F. Ali
February 18, 2023 at 9:56 am
I always enjoy reading your work. Great job!!
Waleed Rishmawi
February 18, 2023 at 3:36 pm
Andrew: glad to hear that and it is an ecouragement to keep going. have a blessed day
Albert van Bemmelen
February 18, 2023 at 3:26 pm
Excellent job on replacing four of those heavily amp rated special IGBT's! And thanks for another datasheet. I wonder why all of them shorted out even when they are 60 Amp rated. Maybe they died because of the higher operating temperature inside caused by the too limited smaller fan? In which case it may happen again?
Waleed Rishmawi
February 20, 2023 at 2:15 pm
Albert: thanks man. they are shorted because the fan is not big enough to generate enough cooling but so far it did not come back. I suggested a better bigger fan but the customer declined the offer. the cold weather is helping to keep enough cooling with the help of this tiny fan but when it gets hot, the cooling will not be enough but it will break again. have a blessed day
LLOYD BOND
February 18, 2023 at 11:22 pm
good diagnostic
Waleed Rishmawi
February 20, 2023 at 2:16 pm
LLOYD: thanks man. have a blessed day
GIFT ELIJAH
February 21, 2023 at 1:35 pm
Keep doing the good work
Excellent repairs well done
Babu M S
February 19, 2023 at 12:35 am
Very good article and well explained.May I get your repair articles to down load.Thank you very much for sharing.
Waleed Rishmawi
February 20, 2023 at 2:18 pm
Babu: thanks man. about the down load, that is a question for Mr Jestine not me. have a blessed day
ivan1
February 19, 2023 at 9:28 am
Hola Son solo los IGBT ,encontre diodos y resistencias quemadas conectadas a dos patas de cada uno de los IGBT,no pudiendo nuca saber sus valores en maquinas de marca STORM no encontrando nunca información ni diagramas ,eran como seis maquinas dañadas, al poco tiempo de uso y el vendedor tuvo que devolver el dinero Mi pregunta es ¿Donde encontrar diagramas'? Agradezco informacion
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Hello, they are only the IGBTs, I found burnt diodes and resistors connected to two legs of each one of the IGBTs, never being able to know their values in STORM brand machines, never finding information or diagrams, there were about six damaged machines, shortly after use and the seller had to return the money My question is where to find diagrams? I appreciate information
Waleed Rishmawi
February 20, 2023 at 2:20 pm
Ivan: sorry but there is no diagrams for these machines, it is a learning process as you go. what model are you dealing with? if the same models were are using here I would be more than happy to help out with part numbers. have a blessed day
Jiří Falta
February 24, 2023 at 1:08 am
kde najít schema pro spotřebyče i za poplatek stáhnout
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where to find a scheme for consumers and download it for a fee
Yogesh Panchal
February 27, 2023 at 9:15 pm
Good fix! Waleed