The welding inverter is modern equipment, the use of which in the welding process makes it possible to achieve very High Quality work and gives the welder the opportunity to work in comfortable conditions. But at the same time, the welding inverter also has a more complex design compared to previous models of welding equipment, which increases the chance of a malfunction during its operation.

As a rule, all malfunctions of the welding inverter can be divided into two groups:

• malfunctions associated with incorrect operation of the electronic "stuffing" of the device

• malfunctions associated with the wrong choice of operating mode.

The second type of malfunction occurs most often, therefore, before contacting a specialized workshop or starting to disassemble the device on your own in order to identify a breakdown, you need to check whether all the settings for the operating mode are set correctly, and in addition, you should read the operating instructions for this device again, to determine if you are making any mistakes in the process. Most manufacturers, when compiling instructions, indicate the causes of malfunctions of the welding inverter that may occur during operation, and also describe how these malfunctions can be eliminated on their own.

Causes of breakdowns of welding inverters and options for their elimination.

There are a number typical faults that occur when we are talking about welding inverters:

• combustion instability welding arc and strong spattering of metal;
• sticking welding electrode;
• lack of welding process when the machine is turned on;
• lack of reaction of the device when it is turned on.

Let us consider in more detail why this or that situation may arise, and what can be done in the event of any malfunction. welding inverters.

• Welding arc instability and strong metal spatter.

This malfunction may occur if you incorrectly selected the current during welding. As a rule, the welding current is selected in accordance with the type and size of the electrode used in welding. But there is one more thing to remember here. important rule: the selected current must also correspond to the speed at which welding is carried out. If the welding speed decreases during operation, then the welding current must also be reduced.

• Sticking welding electrode.

There can actually be several reasons for this type of malfunction. It is possible that during welding, the voltage unexpectedly decreased in the network, which led to a strong sticking of the welding electrode. It can also “stick” even if the inverter is connected to the network with a cable with a too small cross section. Another reason for this "behavior" of the electrode may be poor contact of the electrode with the surface to be welded due to the fact that the surface has undergone oxidation due to exposure to atmospheric oxygen. In this case, welding must be stopped, and the surface of the part must be cleaned from the film.

• Lack of welding process when the machine is turned on.

In the vast majority of cases, this behavior of the welding inverter can be explained by the absence of mass on the surface of the part to be welded. In addition, it would be useful to check the condition of the welding cable - it may be damaged. This situation is quite common in the event that the part being welded has a large weight, as a result of which the fall of the part on the wire can violate its integrity.

• No reaction of the device when turned on.

If nothing happens when the welding inverter is turned on, then the cause of such a malfunction should be sought, in many cases, not in the inverter itself, but in electrical network to which it is connected. The mains voltage may be too low and therefore the machine cannot work. Another reason that the device does not turn on may be an incorrectly selected circuit breaker installed in the shield. A weak switch is able to trip when the inverter is turned on. In addition, turning off the device can lead to the fact that the electricity will disappear throughout the house.

In addition to these malfunctions, there are also interruptions in the operation of the welding inverter, which are not associated with a breakdown of the device, but are the result of a fairly high-quality and timely operation of the protection systems that the inverter is equipped with. So, for example, for a long continuous work the inverter may trip spontaneously. This happens if the device overheats and the temperature protection trips. In this case, you should stop the welding process for about 20-30 minutes, let the machine cool down, after which work can be continued.

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Features of operation and possible faults welding inverters.

Features of operation and possible malfunctions of welding inverters.

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It is well known that the repair of welding machines in the vast majority of cases can be organized and carried out independently. The only exception is the restoration of the electronic inverter, the complexity of the circuit of which does not allow for a full repair at home.

Just one attempt to disable the inverter protection can confuse even an electrical engineer. So in this case, it is best to seek help from a specialized workshop.

The main manifestations of malfunctions of electric arc welding machines are:

• the device does not turn on when connected to the mains and starting;
• sticking of the electrode with a simultaneous hum in the area of ​​​​the converter;
• spontaneous shutdown of the welding machine in case of overheating.

Repair always begins with an inspection of the welding machine, checking the supply voltage. It is not difficult to repair transformer welding machines, moreover, they are picky in maintenance. For inverter devices, it is more difficult to determine a breakdown, and repairs at home are often impossible.

However, with proper handling, inverters last a long time and do not break. Must be protected from dust high humidity, frost, store in a dry place. There are the most typical malfunctions of welding machines, which you can fix with your own hands.

Device won't start

In this case, first of all, you need to make sure that there is voltage in the network and the integrity of the fuses installed in the transformer windings. If they are in good condition, use the tester to ring the current windings and each of the rectifier diodes, thereby checking their performance.

If one of the current windings breaks, it will need to be rewound, and in the event of a malfunction of both, it is easier to replace the entire transformer. A damaged or "suspicious" diode is replaced with a new one. After repair, the welding machine is turned on again and checked for serviceability.

Sometimes the filter capacitor fails. In this case, the repair will consist in checking it and replacing it with a new part.

In case of serviceability of all elements of the circuit, it is necessary to deal with mains voltage, which can be greatly underestimated and is simply not enough for the normal functioning of the welding machine.

Sticky electrode (arc interruption)

The cause of sticking of the electrode and interruption of the arc may be a decrease in voltage due to short circuit in the transformer windings, diode failure or loose connection contacts. Breakdown of the capacitor filter or short circuit is also possible. individual parts on the body of the welding machine.

Organizational reasons, due to which the device does not cook as it should, include excessive length welding wires(more than 30 meters).

If sticking is accompanied by a strong hum of the transformer, this also indicates an overload in the load circuits of the device or a short circuit in the welding wires.

One of the repair options to eliminate these effects can be the restoration of the insulation of the connecting cables, as well as the tightening of loose contacts and terminal blocks.

Spontaneous shutdown

In some cases, repairs can be carried out independently if the device starts to turn off spontaneously. Most models of welding machines are equipped with protective circuit(automatic), triggered in a critical situation, accompanied by a deviation from normal operation. One of the options for such protection involves blocking the operation of the device when the ventilation module is turned off.

After a spontaneous shutdown of the welding machine, first of all, you should check the state of protection and try to return this element to working condition.

If the protective node is triggered again, it is necessary to proceed to troubleshooting using one of the methods described above related to short circuits or malfunction of individual parts.

In this situation, the first thing to do is to make sure that the cooling unit of the unit is working properly and that the overheating interior spaces excluded.

It also happens that the cooling unit does not cope with its functions due to the fact that the welding machine has been under a load exceeding allowable rate. The only right decision in this case is to let it “rest” for about 30-40 minutes, and then try to turn it on again.

In the absence of internal protection, the circuit breaker can be installed in electrical panel. To maintain the normal functioning of the welding unit, its settings must correspond to the selected modes.

So, some models of such devices (a welding inverter, in particular), in accordance with the instructions, must work according to a schedule that involves a break of 3-4 minutes after 7-8 minutes of continuous welding.

Malfunctions of inverter devices

Before repairing an inverter welding machine with your own hands, it is advisable to familiarize yourself with the principle of operation, as well as with its electronic circuit. Their knowledge will allow you to quickly identify the causes of breakdowns and try to eliminate them in a timely manner.

Wiring diagram

The operation of this device is based on the principle of double conversion of the input voltage and obtaining a constant output at the output. welding current by rectifying the high frequency signal.

The use of an intermediate high-frequency signal makes it possible to obtain a compact pulse device with the ability to effectively adjust the output current.

Breakdowns of all welding inverters can be conditionally divided into the following types:

• malfunctions associated with errors in the choice of welding mode;
• failures in operation due to failure of the electronic (converting) module or other parts of the device.

The method for identifying inverter malfunctions associated with malfunctions in the operation of the circuit involves the sequential execution of operations performed according to the principle “from simple damage to more complex failure”. The nature and cause of breakdowns, as well as repair methods, can be found in more detail in the summary table.

It also provides data on the main parameters of welding, providing a trouble-free (without turning off the inverter) operation of the device.

Operation features

Maintenance and repair of welding machines inverter type differs in a number of features related to the complexity of the circuit of these electronic units. To repair them, you will need certain knowledge, as well as the ability to handle such measuring instruments, how digital multimeter, oscilloscope and the like.

Under renovation electronic circuit first produced visual inspection boards in order to identify burnt or "suspicious" elements as part of individual functional modules.

If during the inspection no violations can be found, the troubleshooting continues by detecting violations in the operation of the electronic circuit (checking voltage levels and the presence of a signal at its control points).

This will require an oscilloscope and a multimeter, which should be started only if you have full confidence in your abilities. If you have any doubts about your qualifications, the only right decision would be to take (take) the device to a specialized workshop.

Complex repair specialists impulse devices they will quickly find and eliminate the malfunction that has arisen, and at the same time they will carry out maintenance of this unit.

Self-repair procedure

In the event of a decision to self repair fees - we recommend using the following tips experienced professionals.

If burnt wires and parts are found during a visual inspection, they should be replaced with new ones, and at the same time, all connectors should be plugged, which will eliminate the possibility of losing contact in them.

If such a repair did not lead to the desired result, you will have to start a block-by-block examination of the electronic signal conversion circuits.

To do this, it is necessary to find sources that provide diagrams of voltages and currents, designed for a more complete understanding of the operation of this unit.

Based on these diagrams, using an oscilloscope, you can sequentially check all electronic circuits and identify a node in which the normal signal conversion picture is disturbed.

One of the most complex components of an inverter welding machine is the electronic key control board, the serviceability of which can be checked using the same oscilloscope.

If you doubt the performance of this board, you can try to replace it with a working one (from another working inverter) and try to start the welding machine again.

In the event of a favorable outcome, it remains only to give your board for repair or replace it with a purchased new one. The same should be done if there are suspicions about the serviceability of all other modules or blocks of the welding machine.

In conclusion, we recall that the repair of any welding units(and inverters, in particular) is considered a rather complicated procedure that requires certain skills and the ability to handle complex measuring equipment.

If you have the slightest doubt about your professionalism, you should use the help of specialists and give them the opportunity to return the faulty device to work.

Answer:

Overheating can happen to almost any equipment, especially where there is work with high currents or temperatures. Therefore, overheating of the welding inverter is a common, quite natural thing and you should not rush to get scared of it. Moreover, almost all welding machines today are equipped with overheating protection, which is designed to prevent equipment breakdown due to such situations.

Overheating of the welding inverter occurs if the machine is running long time without a break. In this case, the time period for each specific model will be individual. However, for household welding inverters, it ranges from thirty minutes to one and a half hours (depending on the quality of the components and assembly of the device), for semi-professional models, this interval increases and ranges from an hour to two hours, and professional welding inverters can often work for a very long time.

It should be taken into account that the value of the working time interval also strongly depends on the temperature in environment. On a hot sunny day, overheating can occur much faster than during the cool hours of the off-season. By the way, each device has a built-in ventilation system, otherwise it could not work for even a few minutes. But to make it very large, efficient, but at the same time cumbersome, is impractical. Therefore, than smaller apparatus, so, often, his period of work without rest is less.

How to determine that the welding inverter has overheated? It will turn off and refuse to turn on for a while. This will mean that the protection has worked. However, we do not recommend bringing the case to such a semi-emergency shutdown. Determine the approximate working time period for your tool and give the device a rest in advance so that it does not wear out too quickly.

By the way, it is believed that among household welding inverters, and differs in a long time working interval. That is why these devices are purchased with such pleasure by summer residents who work with them, usually in hot summers. vacation days. From semi-professional and professional equipment well in this regard, the German

The welding inverter differs from the conventional welding machine in an easier and better welding process. However, malfunctions of the welding inverter, due to its more complex device may be more serious and complex.

To determine the cause of the breakdown of the device, you need to diagnose it: check transistors, resistors, diodes, stabilizers, contacts, etc. Each device comes with detailed instructions with a description of the most common faults that you can fix yourself. However, very often repairs may require special equipment: ohmmeter, voltmeter, multimeter, oscilloscope. And you need to know how to use them. And in special cases, knowledge in electronics, the ability to work with electrical circuits is necessary. Therefore, if self-checking and elimination simple faults, described below, did not lead to success, it is better to entrust the repair inverter device masters in the service center.

What are inverter faults?

There are several groups of breakdowns of welding inverters:

• malfunctions arising from non-compliance with the norms of the welding workflow specified in the instructions;
• malfunctions arising as a result of improper operation or failure of the elements of the device;
• damage caused by moisture, dust and foreign objects entering the device.

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Common malfunctions that you can fix yourself

Consider some of the most common malfunctions of welding inverters:

To identify and eliminate the cause of the malfunction, the body of the apparatus is opened and a visual inspection of its contents is carried out.

1. The welding arc is unstable or the electrode spatters the material. The reason for this may lie in wrong choice current. The current strength must correspond to the type and diameter of the electrode and the speed of the welding process. If the current strength is not indicated on the packaging of the electrodes, then you can start supplying current from 20-40 A per millimeter of electrode diameter. When reducing the welding speed, the amperage must also be reduced.
2. The electrode sticks to the material. Often this is due to low voltage in the network, the value of which is less than the minimum allowed when working with the inverter. The reason for sticking of the electrode can also be poor contact in the sockets of the panel, which can be eliminated by fixing the boards more tightly. Using an extension cable with a wire size smaller than 2.5 mm2 or with a wire that is too long (more than 40 m) may reduce the voltage. Burnt or oxidized contacts in electrical circuit can also lower the voltage.
3. There is no welding process, while the machine is connected to the network. In this case, you need to check the presence of mass on the part to be welded. Also check the inverter cable for damage.
4. The device turns off by itself. The device is switched off at the moment the transformer is connected to the network, after which its protection is activated. The reason for this may be a short circuit in the voltage circuit. Protection can be activated not only when the wires are shorted to each other or with the case, but also when the short circuit between the turns of the coils or the breakdown of capacitors. To repair a floor, you first need to turn off the transformer and find the fault, and then insulate or replace the damaged element.

If there is no welding when the machine is switched on, check the connection of the electrode holder cable.

During a long period of operation, the device turned off. Most likely, this is not a breakdown, but an overheating of the inverter. It is necessary to wait 20-30 minutes, and then resume work. You should follow the rules for operating the device: do not overheat it, that is, take breaks in operation, connect appropriate current values ​​\u200b\u200bto it, do not use electrodes of too large diameters.

The transformer emits a strong hum and overheats. Perhaps the reason for this was the overload of the transformer, the loosening of the bolts that tighten the sheets of the magnetic circuit, or the breakdown of the core fastening. Due to the short circuit between the sheets of the magnetic circuit or cables, the device can also hum strongly. Tighten all fastening elements and restore cable insulation.

Welding current is poorly regulated. The reason for this may be breakdowns in the current regulation mechanism: a malfunction in the current regulation screw, a short circuit between the regulator mounts, a short circuit in the inductor, poor mobility of the secondary coils as a result of blockage, etc. Remove the casing from the inverter and examine the current regulation mechanism in order to identify a breakdown.

The welding arc breaks abruptly, and it is impossible to ignite it, only sparks appear. Perhaps the problem lies in the breakdown of the winding high voltage, a short between the wires, or a poor connection to the inverter terminals.

High current consumption at no load. The reason may be the closure of the turns on the coil. You can eliminate it either by restoring the insulation, or by completely rewinding the coil.

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If excessive spatter of the electrode metal occurs during welding, then the cause may be an incorrectly selected value of the welding current.

If a smell of burning and smoke appeared from the body of the device, this may indicate a serious breakdown. AT this case You may need a qualified repair at a service center.

To identify a malfunction, the case is first disassembled. Perform a visual inspection of parts for damage, cracks, burnt contacts and swelling of capacitors. They also check the soldering points of parts and contacts on the inverter boards. Often the causes of a malfunction lie precisely in poor-quality soldering, they can be easily eliminated by re-soldering the parts.

All defective parts should be unsoldered and replaced with new ones corresponding to this model of the device.

You can select parts in accordance with the markings indicated on the body of the device or in a special guide.

You need to solder the parts with a soldering iron that has a suction, which will make the work convenient and fast.