Modern welding machines are complex electrical equipment. Come on the process of malfunction may be a consequence of completely different reasons. Having understood in them, you can easily make quality welding machine repair with your own hands.

The main causes of faults

It should be noted that the main characteristics of the welding machines are reliable operation and simplicity of the design. But sometimes even the best welding machines fail.

The main reasons for this may be:

• improper operation of devices;
• incorrect connection of the device;
• various indicators of the power supply voltage and current.

Often, a consequence of equipment breakdowns is their use in difficult weather conditions (snow, rain, increased humidity) and in highly polluted rooms.

The most vulnerable place of welding machines includes a terminal block. It is carried out by connecting cables for welding. The presence of poor contact with the maximum current value is the cause of strong overheating of the connecting elements and wires. At the ends of the winding, insulation is melted on the wires. For this reason, the electrical circuit occurs. In this case, the repair of welding machines provides for cleaning contacts and their dense docking with a heating compound.

Diagnostics of breakdowns of welding machines

There are such main malfunctions of welding machines:

• equipment does not turn on;
• spontaneously turns off;
• buzzing is very buzzing;
• overheat;
• cutting the welding arc;
• poor current regulation;
• overweight electricity consumption.

The reasons for the fact that the device does not turn on may be:

• insufficient voltage in the network;
• the machine gun on the shield;
• equipment does not work.

Spontaneous shutdown of the welding machine occurs when the protective device is triggered. This is a consequence of closures between:

• wires;
• housing and wires;
• coil coils;
• magnetic pipeline sheets;
• capacitor samples.

Troubleshooting provides:

• turning off the welding from the network;
• search for a defect;
• restoration of isolation or replacement of the capacitor.

And how to make the welding machine in good condition when he is very buzzing? The source of increased noise is to overheat the equipment. It may arise as a result:

• weakening bolts connecting the elements of the magnetic pipeline;
• long work apparatus;
• circuits between welding cables;
• mechanism breakdowns for moving coils;
• core fastening disorders.

To eliminate these breakdowns by:

• pulling fasteners;
• repair of mechanisms that attach coils and core;
• restoration of insulation in cables.

The occurrence of excessive overheating of the welding machine is associated with:

• using current that exceeds the allowed value;
• the use of electrodes with a maximum diameter;
• long functioning.

The main solution to this problem is to take breaks when welding and use the appropriate electrodes. Strong overheating of the apparatus can cause closure between coils. Isolation melts and sharp smell of Gary appears. Such a breakdown indicates that they will have to engage in the restoration of cable insulation or even worse than the turning of the coil's turns.

The appearance of small sparks instead of the arc says that it happened. The causes of this malfunction are:

• breaking winding with high voltage on the chain;
• closure of welding wires;
• bad cable contact with terminals.

Repair of the arc welding machine provides for checking windings and wires. Contacts are cleaned and tightly attached to the terminals.

Insufficient adjustment of the current value during welding can be caused:

• breakdown screw controller;
• violation of the movement of coils;
• closure in throttle coil or between clips in the regulator;
• getting small items.

To eliminate problems, remove the protective cover and conduct studies of certain elements for faults. In case of discovery of foreign objects, they need to withdraw.

Excessive electricity consumption in the absence of loads indicates a possible closure of turns of the winding. This problem is solved by replacing the isolation or rewind of the coil.

Welding Inverter Repair Nuances

The most convenient devices for welding work are inverters. On the one hand, with their help, better welding is carried out. But on the other hand, they are less reliable devices compared to transformer or rectifier devices. This is explained by the fact that the inverters are electronic devices.

Diagnostics and repair of inverter welding machines include checking the effective operation of diodes, transistors, stabilitons, resistors and other elements included in chips. When repairing inverter welding machines, it is necessary to use different measuring equipment: a voltmeter, a multimeter, oscilloscope. That is, you need to have at least a little experience with electrical circuits.

The main feature during the repair of inverter welding is that the device malfunction is very difficult. The inverter is a few electronic modules, the main of which are the input, output rectifiers, transistors and control board with keys.

For this reason, the repair of the inverter's welding machine is reduced to a permanent performance test:

• transistors;
• driver elements;
• rectifiers;
• control boards.

The weakest elements of welding inverters include transistors. The transistor failed has a cracked body and burnt conclusions. It should be replaced. If at first glance it is difficult to determine the non-working transistor, then they are "nicknamed" by a multimeter. Instead of a faulty transistor, it is necessary to put only the element similar to characteristics.

Transistor breakage can be a consequence of the failure of the driver. This element is checked using an ohmmeter. A bad driver is falling and changing to a similar element.

Checking diode bridges (this is also called the output and input rectifiers) is carried out by removing them from the board. Save them from the cable will make it easier to work. Only so the search for a damaged rectifier will not depend on the chain - it can close. The punched diode is by calling the entire group of rectifiers. For its effective seizure, a soldering iron with suction is used.

The most complex module inverter is the key control board. It must end the repair of the inverter. All control signals that enter the valves of the module are checked using an oscilloscope.

Welding apparatus repair video: