The welding inverter provides good quality carrying out welding work, creating the most comfortable working conditions for the welder. However, these advantages lead to increased complexity of its design. This can cause various malfunctions of the welding inverter and reduce its reliability.

Features of inverter repair

Unlike conventional welding machines, which are electrical products, an inverter for welding is electronic device. Consequently, diagnostics and repair of inverter welding machines are carried out by checking the operating condition of diode bridges, transistor connections, zener diodes and other parts that are part of electronic circuits. In this case, you need to have skills in handling oscilloscopes, voltmeters, multimeters and others measuring instruments.

Home distinctive feature When repairing a welding inverter, it is difficult to determine the nature of the breakdown and detect the failed part. Therefore, it is very often necessary to diagnose all components of the electrical circuit.

Based on the foregoing, we can conclude that it is necessary to have minimal knowledge in the field of electronics and be able to understand the design electrical diagrams. If such skills and abilities are absent, then it is not recommended to undertake independent repair of such a device, so as not to waste extra effort and time.

Operating principle of the inverter

Principle of operation inverter devices consists of sequential (step-by-step) transformation of the incoming electric current signal:

• the process of rectifying incoming network currents using a special rectifier;
• the process of converting rectified currents into alternating high-frequency signals;
• the process of reducing high voltage currents to welding voltage, occurring on a power transformer;
• transformation alternating current with high frequency D.C., occurring using the output rectifier.

To perform such operations, the design of the welding inverter has several modules with electronic filling. The main module is the input current rectifier. Then there is a control board on which transistors (switches) are located, and it ends with a rectifier for the output signals.

At the same time, in devices different manufacturers having different models, the layout of the unit components can be very diverse, but the installation of the main components will always remain unchanged.

Therefore, knowing the basic operating principle of such units and the location of the main modules of their design, it is possible to diagnose possible faults and carry out the necessary repairs.

Types of main faults

If the welding inverter fails, the first thing you should do is check its transistors, since they are one of the most weak points such units. Initially, a visual inspection of the transistors should be carried out. Such a broken part is very easy to identify: it has a broken or cracked case with burnt-out leads at the solder points on the board. This part needs to be replaced immediately.

New transistors should be installed on a special thermal paste. It will ensure heat removal from the transistor to a radiator made of aluminum. But very often a visual inspection does not reveal faulty elements, then you should make a “diagnosis” using a multimeter.

Replacement faulty elements carried out according to precisely specified parameters. In some cases, it is possible to supply analogue parts, and the required parameters can be determined from the datashift. If replacing the burnt-out transistors does not help, you need to move on to further diagnostics.

IN normal mode operation, transistors cannot simply fail; most likely, this is due to the incorrect operation of other elements. Most often this is the driver. It is checked with an ohmmeter. If faulty parts are found, they must be removed and replaced with similar parts.

Then the input and output current rectifiers, which consist of diode bridges, are checked. They are installed on the radiator and are reliable units welding inverters. But they can also fail. Their functionality is checked using a voltmeter.

Control board fault

It is best to check diode bridges by unsoldering the wires from them and then detaching them from the board. This can make everything easier further work and there will be no doubt when a short circuit occurs in the entire inverter circuit.

The check follows a fairly simple algorithm. It is necessary to “ring” the entire group of parts. If a “short” is detected, then you should search for a broken diode. Once it is detected, the diode should be carefully removed and replaced.

If, after carrying out all the above steps, the welding machine still does not work, you should test the control board. It monitors the operation (control) of the keys. The reliability of all equipment will depend on the reliability of such a board.

To carry out competent and qualified repair of the inverter, it is necessary to check for the presence of the necessary signals that produce its operation. These signals must be sent to the gate buses of the key module. You can perform a similar check using oscilloscopes.

Periodically, high heating of the inverter housing may occur. This may be due to violations of the rules for using the unit and wrong choice values ​​of current used for welding. This can also occur when the electrodes are incorrectly selected or the unit is operated for too long. To avoid such difficulties when using the inverter, it is necessary to observe optimal modes works that are specified in the technical passport.

You can fix inverter malfunctions yourself, but this can only be done if you have the necessary diagnostic tool and experience in using it. Otherwise, it is better to seek help from specialists.

An inverter welder differs from a 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 a device failure, you need to diagnose it: check transistors, resistors, diodes, stabilizers, contacts, etc. Each device is supplied 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 of electronics and the ability to work with electrical circuits are required. Therefore, if self-checking and eliminating simple faults described below did not lead to success, it is better to entrust the repair of the inverter apparatus to the specialists at the service center.

What are the types of inverter malfunctions?

There are several groups of breakdowns of welding inverters:

• malfunctions arising due to non-compliance with the welding workflow standards specified in the instructions;
• malfunctions arising as a result of incorrect operation or failure of device elements;
• breakdowns resulting from moisture, dust and foreign objects entering the device.

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Common faults that you can fix yourself

Let's look at some of the most common malfunctions of welding inverters:

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

1. The welding arc burns unsteadily or the electrode spatters material heavily. The reason for this may lie in the wrong choice of 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 electrode packaging, then you can start supplying current from 20-40 A for each millimeter of electrode diameter. When the welding speed is reduced, the current must also be reduced.
2. The electrode sticks to the material. This often happens due to low voltage in the network, the value of which is less than the minimum permissible when working with an inverter. The cause of electrode sticking can also be poor contact in the panel sockets, which can be eliminated by fixing the boards more tightly. Using an extension cord 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 reduce tension.
3. There is no welding process, while the device is connected to the network. In this case, you need to check the presence of mass on the part being welded. Also check the inverter cable for damage.
4. The device turns off spontaneously. The device is switched off when the transformer is connected to the network, after which its protection is triggered. The reason for this may be a short circuit in the voltage circuit. The protection can be activated not only when the wires are shorted to each other or to the housing, but also when there is a short circuit between the turns of the coils or a breakdown of the capacitors. To repair a hollow part, you first need to disconnect the transformer and find the fault, and then insulate or replace the damaged element.

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

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

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

Welding current is poorly regulated. The reason for this may be a breakdown in the current regulation mechanism: a fault 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 clogging, etc. Remove the casing from the inverter and examine the current regulation mechanism to identify the breakdown.

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

High current consumption at no load. The reason may be short circuit of the turns on the coil. It can be eliminated either by restoring the insulation or by completely rewinding the coil.

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

If a burning smell and smoke appear from the device body, this may indicate a serious breakdown. IN in this case You may need qualified repairs at a service center.

To identify the malfunction, first disassemble the housing. Carry out 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 malfunctions lie precisely in poor-quality soldering; they can be easily eliminated by re-soldering the parts.

All faulty parts should be removed and replaced with new ones corresponding to the given model of the device.

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

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

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 circuitry of which does not allow for a full repair at home.

Just trying to disable the inverter protection can baffle even an electrical specialist. So in this case, it is best to seek help from a specialized workshop.

The main manifestations of problems with electric arc welding machines are:

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

Repairs always begin with an inspection of the welding machine and checking the supply voltage. Repairing transformer welding machines is not difficult, and they are not picky about maintenance. With inverter devices, it is more difficult to determine a breakdown, and repairs at home are often impossible.

However, if handled properly, inverters last a long time and do not break down. Must be protected from dust high humidity, frost, store in a dry place. There are the most typical malfunctions of welding machines that you can fix yourself.

The device does not 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 working order, you should use a 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 rewinded, and if both are faulty, it is easier to replace the entire transformer. The 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 of checking it and replacing it with a new part.

If all elements of the circuit are in working order, you need to deal with mains voltage, which can be greatly underestimated and is simply not enough for the normal functioning of the welding machine.

Electrode sticking (arc interruption)

The cause of electrode sticking and arc interruption may be a decrease in voltage due to short circuit in the transformer windings, faulty diodes or loose connecting contacts. A breakdown of the capacitor filter or a 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 from 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 could be restoring the insulation of connecting cables, as well as tightening loose contacts and terminal blocks.

Spontaneous shutdown

In some cases, repairs can be carried out independently if the device begins to turn off spontaneously. Most models of welding machines are equipped protective circuit(automatic), triggered in a critical situation, accompanied by 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 spontaneous shutdown of the welding machine, first of all, you should check the state of the protection and try to return this element to working condition.

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

In this situation, first of all, you should make sure that the cooling unit of the unit is working normally and that overheating internal spaces excluded.

It also happens that the cooling unit does not cope with its functions due to the fact that the welding machine was under a load exceeding permissible norm. The only correct solution 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 safety circuit breaker can be installed in electrical panel. To maintain normal functioning of the welding unit, its settings must correspond to the selected modes.

Thus, some models of such devices (welding inverter, in particular), in accordance with the instructions, must work according to a schedule that requires 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 its electronic circuit. Knowing them will allow you to quickly identify the causes of breakdowns and try to eliminate them in a timely manner.

Electrical diagram

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

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

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

• malfunctions associated with errors in choosing the welding mode;
• operational failures caused by failure of the electronic (converter) module or other parts of the device.

The method for identifying inverter faults associated with disturbances in the operation of the circuit involves sequential execution of operations carried out according to the principle “from simple damage to more complex damage.” 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 welding parameters, ensuring trouble-free (without turning off the inverter) operation of the device.

Features of operation

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

Under renovation electronic circuit First, a visual inspection of the boards is carried out in order to identify burnt or “suspicious” elements within individual functional modules.

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

To do this, you will need an oscilloscope and a multimeter, which you should start working with only if you have complete confidence in your abilities. If you have any doubts about your qualifications, the only right decision is to take (take) the device to a specialized workshop.

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

Self-repair procedure

If a decision is made to self-repair fees - we recommend using the following tips experienced specialists.

If detected during visual inspection burnt wires and parts should be replaced with new ones, and at the same time all connectors should be reconnected, which will eliminate the possibility of loss of contact in them.

If such repairs do not lead to the desired result, you will have to begin a block-by-block examination of the electronic signal conversion circuits.

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

Focusing on these diagrams using an oscilloscope, you can sequentially check all electronic chains and identify a node in which the normal signal conversion pattern is disrupted.

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 have doubts about the functionality of this board, you can try replacing it with a working one (from another, working inverter) and try to start the welding machine again.

If the outcome is favorable, all that remains is to send 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 would like to remind you that the repair of any welding units(and inverters, in particular) is considered a rather complex 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.

Welding inverter is modern equipment, the use of which in the welding process makes it possible to achieve very High Quality 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 occurring during its operation.

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

• malfunctions associated with improper operation of the electronic “stuffing” of the device

• malfunctions associated with incorrect choice of operating mode.

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

Causes of breakdowns of welding inverters and options for eliminating them.

There are a number typical faults, which arise when we're talking about about welding inverters:

• combustion instability welding arc and strong metal splashing;
• sticking welding electrode;
• lack of welding process when the machine is turned on;
• lack of response from 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 of welding inverters.

• Instability of the welding arc and strong spattering of metal.

This malfunction can occur if you select the wrong current when welding. Usually, welding current is selected in accordance with the type and size of the electrode used for welding. But here it is necessary to remember one more thing important rule: the selected current must correspond to the speed at which welding is carried out. If the welding speed decreases during operation, then the welding current must be reduced.

• Welding electrode sticking.

In fact, there may be several reasons for this type of malfunction. It is quite possible that during welding the voltage in the network suddenly decreased, which led to severe sticking of the welding electrode. It can also “stick” if the inverter is connected to the network with a cable with a cross-section that is too small. 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 of 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 lack of mass on the surface of the part being welded. In addition, it would be useful to check the condition of the welding cable - it may be damaged. This situation occurs quite often if the part being welded is heavy, as a result of which the part falling onto the wire can damage its integrity.

• The device does not respond when turned on.

If nothing happens when you turn on the welding inverter, 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 device cannot operate. Another reason that the device does not turn on may be an incorrectly selected circuit breaker, installed in the shield. A weak switch can turn off when the inverter is turned on. In addition, turning off the device can lead to a loss of electricity throughout the house.

In addition to the indicated malfunctions, there are also interruptions in the operation of the welding inverter, which are not related to the breakdown of the device, but are a consequence of the fairly high-quality and timely operation of the protection systems with which the inverter is equipped. So, for example, with long-term continuous operation The inverter may turn off 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, allow the device to cool, after which work can be continued.

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Features of operation and possible malfunctions welding inverters.

Features of operation and possible malfunctions of welding inverters.

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