Wednesday, March 21, 2012

Welder repairs after loud bang!!! - MIG Welding Forum

There's a pre-charge circuit in inverters which on start up, charges the main capacitors through a resistor slowly to avoid a current surge into the main capacitors, which would blow fuses and maybe damage the inverter. When the capacitors are charged (about half a second) the inverter is ready to weld and a relay shorts out the resistor and powers the welder properly. I'd check the relay and the resistor. I recall Gys have a more complicated arrangement with relay contacts to connect in the resistor and another set to make the connection after the pre-charge is complete. It could be that the relay contacts became stuck and have now been damaged, in which case it's replacing the relay.

However, this could be all sorts of things, some very hard to diagnose without a service manual and just by using a multimeter and deduction. For instance, these are dual voltage machines so there'll be circuitry to detect the voltage and adjust for it.

If you look on the WWW there are people offering inverter repairs. I gather that their prices start at about £75, but you'd have to contact them and ask. This is a pretty old machine and you'd have to weigh the cost of repairs against buying a new inverter with a warranty.

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