Welding Machine Powers On But Does Not Weld Repaired
This welding machine was brought to my shop for repair and as I understood from the customer that it powers on but does not weld.
Look at this dust covering this welding machine which shows that it has not been maintained
for a long time and I expect to see many faults in it.
Here is another fault that I took care of right away and now I am concentrating on why this machine is not welding? Let us find out.
After cleaning, I proceeded to checking parts on this machine for sometime obvious faults…
This is a very important test to do by checking the ohm reading on the output of this welding machine and I should be getting a high reading of ohms.
No reading is an indication of a loose connection either on board or one of the components is burnt.
It is making a connection but not the best connection so I checked further for more issues.
The connection from the lower metal part to the top one is missing and I think I just found the fault here.
It seems like the whole metal piece need to be changed and the lower part where it attached to the board is loose too and need some attention.
That is the lower side and as seen, it is really bad. This area has to be cleaned, sanded to make a better joint, add a new metal piece and hope for the best.
I cut a metal piece, made a hole to fit the screw in and I installed it on board.
Tightened the screws, added a fresh solder after cleaning the joints and the job is done.
Let us see if we get any voltages out on the negative and the positive terminals of the machine.
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 Shorted IGBT On A Cheap Welding Machine Repaired. Model: Sniper
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Parasuraman S
September 15, 2022 at 8:03 am
Very determined fix on an otherwise tempted discarding! Well done!
Tayo
September 15, 2022 at 9:42 am
Easy fix for you Waleed.
Thanks for the tip on checking the leads for resistance.
Albert van Bemmelen
September 15, 2022 at 12:29 pm
Very decent repair of a device the owner hopefully takes more care now!
Paris Azis
September 15, 2022 at 4:12 pm
Good job, Waleed! This is the worst welding machine design I have ever seen... Too many problematic circuits in it, especially the little output mosfets driver PCB...it oftentimes causes overheating of the output transistors, which in turn triggers the relevant protection circuit rendering the machine inoperative until it gets cold again or, in the worst case, one or more of the output mosfets gets shorted...Hopefully they have resolved this problem on their late models...
Waleed Rishmawi
September 15, 2022 at 8:56 pm
Paris: this is a turkish made welding machine and they were built in a very cheap way to attract none professionals but sad to say it is used by professionals as well and so often I get his kind in the shop for repair. have a blessed day
AdamS
September 15, 2022 at 5:53 pm
The welding machine master strikes again!
Waleed Rishmawi
September 15, 2022 at 8:57 pm
AdamS: thanks man. have a blessed day
HECTOR DELATORRE
September 15, 2022 at 9:22 pm
really nice article continue to do a good job
Waleed Rishmawi
September 17, 2022 at 2:46 pm
Hector: thanks man. have a blessed day
GIFT ELIJAH
September 16, 2022 at 11:11 am
Good fix detailed checks, but what is the expected ohms value from the two outlet points?.
Still learning.
Waleed Rishmawi
September 17, 2022 at 2:49 pm
Gift: thanks man. the ohm readings is different from one machine to another but usually should be a high ohm reading some 700 ohm and higher. if very low ohm reading or no reading, check the Mosftes, or IGBT's or the connections inside the machine. have a blessed day
Yogesh Panchal
September 17, 2022 at 2:22 pm
Good Repair! Waleed
Highly Recommend to wear face Mask while Blowing Dust,Take care of the health first.Now a days repairing of electronics equipment's need many another skills to Learn as you did here by making copper strip and arranged properly to fit it.
Waleed Rishmawi
September 19, 2022 at 3:42 pm
Yogesh: thanks for the advice but I always put a mask on when I plow out dust and I usually do it in a any open space not inside. have a blessed day
William Shaw
September 20, 2022 at 9:22 am
Great pictures documenting the repair. And thank you, Gift, for asking that question.
Aword J Stephen
September 22, 2022 at 7:13 am
Well that was very good,boy I had one at my work shop for a costumer and it wasn't welding, power is going in the machine comes on but no welding, I think I will speak to the costumer, brilliant brilliant,,