Equipment such as a welding machine has always been in demand. Especially if he small sizes, compact, operating at a voltage of 220 volts, which is very convenient when conducting welding work in places where it is difficult to use bulky and powerful devices. For example, on construction sites, in car repair services, household appliances etc.

But, most importantly, the welding machine, the weight of which seems ridiculous for such equipment, sometimes it does not exceed 5 kg, because of its compactness and mobility it is easy to use when repairing personal equipment, construction individual houses, building some metal structures on the summer cottages etc. In a word, such a welding baby will come in handy everywhere.

Now modern technologies allow to produce a wide range and a large number of compact and mobile welders, which are used not only in industry, but also at home. You can almost buy them. in any store for the sale of equipment. Big choice and reasonable price of welding machines allow everyone to buy them without any problems.

Currently, welding machines are very popular. different models Latvian company Resanta. This equipment High Quality. In Russia, the demand for Resant welding machines is very high. They are convenient to transport, because the size and weight allow you to transport equipment even in the trunk passenger car. And carry over short distances to one person.

The advantages of Resanta were appreciated not only by professional welders, but also by amateurs who do not have sufficient experience in welding.

The company produces two types of welding equipment: Resanta welding machine and Resanta welding inverter. The difference between them is that the first type is a transformer unit, and the second is an inverter unit. Both of them differ from each other in different indicators.

However, no matter how reliable the device is, and no matter what its margin of safety, sooner or later some part may fail, and it will need repair. Just as there is no perpetual motion machine in nature, so there are no eternal mechanisms. Breakdowns are inevitable for both the Resant welding machine and the Resant inverter. Consider common signs and the reasons for both types of welding equipment of a Latvian company, leading to repairs.

Signs and causes of breakdowns of the welding inverter

Signs by which it can be determined that the Resant welding inverter repair required:

• electrode sticking
• instability electric arc
• no arc
• device overheating
• inverter does not turn on

Causes of the malfunction

Sticking of the electrode occurs in the following cases:

• low voltage
• using an extension cable with a cross section of less than 2.5 mm
• burnt contacts
• poor cable contact

Arc instability is caused by:

• incorrect adjustment of the welding current
• discrepancy between the type and diameter of the electrodes

The absence of an arc in caused by the following reasons:

• cable break
• inverter overheating
• lack of "mass"
• failure of the printed circuit board, where one or even several parts failed

Machine overheating can happen when:

• it works long time at full load without interruption
• cooling fan failed
• there is a large layer of dust on the parts of the printed circuit board

Causes when the inverter does not start after pressing the "Start" button. those. does not start working, may be the following:

• completely absent or low voltage food
• something is faulty: cable, socket or switch
• on the printed circuit board an element has broken
• extension needs to be replaced

Breakdown of the welding machine

Causes of breakdowns, due to which often welding units being repaired:

Any manufacturer values ​​its reputation and will not produce low-quality products. However, no matter how good the assembly of the same welding machine, in the process of working from vibration, constant transportation, etc., contacts on terminal blocks, to which the welding cables are connected, weaken. And as a result, strong heating of parts occurs at the junctions, which leads to their destruction and short circuit in the network, and, consequently, to repair. To prevent this, you need to regularly monitor the contacts on the terminals, and, if necessary, sort out and clean the connecting contacts, thereby ensuring tight contact of all parts.

It often happens that the welding machine during operation suddenly can turn itself off. And this happens because in the chain high voltage happened short circuit. In this case, it is necessary, by establishing a defective place, to eliminate the malfunction.

The weakening of the bolts tightening the transformer plates, overloads in the operation of the transformer block of the welding machine, as well as the weakening of the core fastening or the mechanism for moving the coils lead to overheating of the transformer of the unit.

If the welding machine overheats, then it needs to take a “breather”. Overheating of the equipment is possible during his intensive work. In such cases, so that the unit does not fail, it is recommended to reduce the operating current or use electrodes of a smaller diameter, otherwise the matter may end in repair.

In the case when the device “does not pull”, the cause should be sought in the mains voltage or welding current regulator.

The main types of repair work

Some minor breakdowns of Resanta can be fixed by yourself, without resorting to the help of specialists. But it also happens that a serious repair is required. In this case, the best contact the service center. There, for example, they can replace:

• fan
• inverter boards
• transformer
• diode rectifier
• capacitors
• and other details

As well as repair:

• control boards
• power supply
• control module
• IMS module
• main board

To repair your welding machine less, try to operate it correctly. And then it will not be necessary to spend money on repairs often.

The welding inverter is modern equipment, the use of which in the welding process allows to achieve a very high quality of work and provides the welder with 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 wrong choice 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. Usually, 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.

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 works for a 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, the smaller the device, the less often its period of work without rest.

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

Here, the repair of the TELWIN Force 165 welding inverter will be considered. For those who are not familiar with the device and circuitry of the welding inverter, we suggest that you first familiarize yourself with the materials on this topic, namely:

In these two articles, using the example of a real TELWIN Force 165 device and a circuit diagram of TELWIN Tecnica 144-164 welding inverters, it is described in detail electronic stuffing and the purpose of each circuit element.

But let's get back to our faulty machine - the TELWIN Force 165 welding inverter. According to the owner, the machine worked properly, but suddenly, after a short break in work, it completely refused to perform its duties. When trying to start work, the spark did not appear, and an unnatural sound for regular work"hum" and "squeak".

According to the owner, it was also known that the device seemed to be working - the noise of the blower fan was heard, the indicator of normal operation turned on. And this indicates that the inverter transistors are working.

One got the impression that the welding inverter "goes into protection" - the internal protective circuits are triggered, which are part of any pulse unit, especially such a powerful one.

I started troubleshooting the welding inverter in an unusual way. The instrument did not turn on.

I had not come across such devices before, and they were new to me. Therefore, the first thing I did was open the case and began to check all the details hitherto known to me with a multimeter.

I found familiar elements on the printed circuit board of the welding inverter: a fan, a powerful diode bridge (a radiator is installed on it), high-voltage electrolytic filter capacitors, an EMC filter, key powerful inverter transistors (installed on a radiator), a pulse transformer, an electromagnetic relay ...

An unpleasant surprise turned out to be that the surface of the printed circuit board was filled with some kind of varnish, which made it difficult to read the markings of SMD elements and microcircuits.

Also found protective elements. One of them is a thermal fuse at 90 0 C. It is glued to the radiator of the diode bridge.

As far as I know, such thermal fuses work tightly, that is, if they heat up above their response temperature, they open forever. Similar thermal fuses can be found in power transformers. There they are included in the primary circuit and glued to it. Protect the transformer from overheating. Sometimes it can be falsely judged that the primary winding of the transformer is open, although it is worth removing (or short-circuiting) this very thermal fuse, as it turns out that the transformer is working.

Therefore, the first thing I checked was the integrity of the thermal fuse at 90 0 C. It turned out to be working.

In addition, on one of the radiators, to which powerful inverter key transistors are attached, there is also temperature sensor. Outwardly, it is very similar to the KSD series thermal switch, which is used in thermopots, water heaters and other household electrical appliances.

The peculiarity of these thermal switches is that their contacts close again if the temperature drops below a certain value. It is clear that this temperature sensor monitors the heating of powerful key transistors and, if there is overheating, temporarily disables the operation of the welding inverter. As soon as the radiators, and, consequently, the transistors, cool down, the device will start up again and will work in normal mode.

When checking the thermal switch, it turned out that it was also working. Well, well, let's look for a malfunction further.

After a short search, it was decided to test the powerful rectifier diodes. On the printed circuit board, they are located in a row and are securely screwed to the radiator with screws. The pages of the site have already talked about how to check the diode.

Labeled as 60CPH03. These are ultra-fast dual diodes VS-60CPH03.

After checking, it turned out that all three dual diodes were approximately faulty. But this is just an assumption, since the diodes are soldered into the circuit, and it is impossible to say 100% that they are faulty. Despite this, it became clear in which direction to "dig" further.

It would be possible to understand the problem without a diagram, but it is more interesting with it, especially since the repair manual for TELWIN Tecnica 144-164 welding inverters was at hand, which, frankly, differ little in their composition and circuitry from TELWIN Force 165. If you look at circuit diagram, then you can see that even if one of the 60CPH03 dual diodes breaks down, all other diodes will also be “faulty” during the check if they are not removed from the board and checked individually. Here is a piece of the circuit - the output rectifier.

As it turned out, it is not so easy to solder these very diodes. Firstly, the soldering is very decent and of high quality. And how is it different here, because huge currents flow in the power section of the welding machine, up to 130 amperes! The slightest lack of solder and the contact point will heat up, and this will subsequently lead to a malfunction. Therefore, the Italians do not spare solder and reliably flavor the contact point with it.

Do not forget that modern electronics are made using lead-free solders, and their melting point is usually higher than that of conventional tin-lead.

Before soldering the diodes, it is necessary to dismantle the radiator. The screws that secure the diodes to the radiator are non-standard, but you can unscrew them with pliers.

For desoldering, it is better to use a more powerful soldering iron. It is better to take an ordinary soldering iron with a power of 50 watts, otherwise the desoldering will turn into torment. You can, of course, use a 40-watt soldering iron, but this will require skill and a lot of patience. It is necessary to have time to warm up all 3 outputs of the diode at the same time.

When dismantling, you can try using a copper braid or desolder to remove solder. True, if the soldering iron is low-power (for example, 40 watts), then there will be little sense from them. The solder will solidify instantly.

Despite the difficulties caused by the low power of the soldering iron (I have it at 40 watts) and the burnt copper tip, I still managed to solder the dual diodes. Unfortunately, not without "jambs".

I tore out the through metallization of copper tracks with roots. Oh well, no problem. We'll clean it up and fix it up.

It turned out that one of the diodes was broken - the rest were intact. It is worth noting that both diodes, which are part of one dual diode, turned out to be broken. Now this is not a diode - but a "sieve" - ​​an ordinary conductor in a beautiful case.

If you look at the circuit, then the diode, which is indicated by a red circle, “flew out”.

Let me remind you that a piece of the circuit is taken from the manual for TELWIN Tecnica 144-164. And he repaired TELWIN Force 165. The Telvin Force 165 does not have an L1 inductor (choke) on the board and, apparently, it should not be, since seat not on the board for it. So don't pay any attention to her. In reality, this coil is made of copper wire large section to withstand currents up to 140 amperes.

It was decided to leave the device alone and look for a replacement for the faulty VS-60CPH03 diode. Finding a replacement for the 60CPH03 diode was not so easy. It was not possible to buy this radio component on the Internet. For some reason, such a detail is a rarity in online stores (perhaps everything has already changed). I had to go to the radio market and buy there.

An analogue of a diode with marking was bought STTH6003CW. The price turned out to be decent, and it was not easy to find the right one.

The parameters of STTH6003CW are the same as those of VS-60CPH03, namely:

Frame - TO-247;

Maximum current in direct connection I F(AV)– 30A for 1 element (60A for both diodes);

Permissible reverse voltage VRRM– 300V;

Recovery time (or performance) t rr (max)– 50 ns (50 nanoseconds).

Dual diode STTH6003CW refers to the so-called fast diodes. Bourgeois call such diodes Ultra-fast, Hyperfast, super-fast, Stealth diode, High frequency secondary rectifier etc. In general, as soon as they do not try to emphasize their steepness.

The main feature of a fast diode is the ability to quickly open (pass current) and also close quickly (not pass current). This means that it can operate at high frequencies. This is required for operation in the welding inverter rectifier, since it is required to rectify high-frequency current - tens of kilohertz.

Therefore, it is worth replacing such diodes only with high-speed ones!

To replace a diode VS-60CPH03 fit STTH6003CW, FFH30US30DN. All these diodes are analogues and are great for replacing each other. Actively used in welding machines. Also suitable STTH6003 TV , but it has a different body ( ISOTOP), although if there is no other, then if you wish, you can contrive and screw it somewhere.

When installing diodes on a heatsink, it is imperative to use a heat-conducting paste (for example, KPT-8).

You should not be greedy, but you should not over-paste the place of thermal contact. We apply a small, even layer of paste to the area of ​​​​contact between the diode body and aluminum radiator. Then we securely fasten the diode case to the radiator with a screw.

The installation of diodes on a radiator should be taken seriously. During operation, the diodes get very hot and the slightest difficulty with cooling will cause them to overheat and fail.

When installing diodes, it is necessary to solder the junctions of the leads and contacts of the copper tracks as best as possible. This is very important, since the currents are simply huge and if you cheat, then nothing good will come of it.

If, during dismantling, copper nickels and copper tracks were “torn off”, then they can be built up with tinned copper wire and soldered with high quality. Purely electrical contact not enough - soldering must be reliable.

After replacing the faulty diode, the device started working.

An archive with diagrams for welding machines TELWIN Tecnica 141-161, TELWIN Tecnica 144-164 and TELWIN Tecnica 150, 152, 170, 168GE can be downloaded and. File size - 4.4 Mb.

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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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