Electronic welding machine errors and solutions at home

Welding machine shows OC light, not working

Electronic welding machines sometimes encounter unexpected problems during use. One of the most common errors is that the machine does not work and shows the OC light, which is a sign of an overloaded or overvoltage power source. At that time, the system automatically shuts down to protect the device from risks such as electric shock, fire, explosion, or reduced machine life. To fix it, simply disconnect power for about 5 minutes, then restart. If you see the OC indicator light, this is a warning that the device is in protection mode.  

Welding machine burned out

Additionally, there are cases where the device does not work at all and has no response. This may stem from a number of reasons such as the power source not being connected properly, the power board relay being faulty, or the machine's capacity not being able to handle large welds. Sometimes, damaged internal components such as capacitors, diodes, thermistors or rectifier bridges are also the cause of this situation.  

If you encounter errors related to burned components or internal damage, you should not arbitrarily repair them to avoid making the situation more serious. Please bring the device to an official warranty center or contact the seller for support and proper handling.  

The electronic welding machine has an electric leak

When using an electronic welding machine, if you detect an electrical leak, you can check with a multimeter. Start by measuring from the case to the weld post.  

If measured on the outside of the welding machine and the result is about 80V, this is a safe level and does not pose a danger to the user. However, if you check the plug and the meter display is unstable, it is possible that the machine has an electrical pulse leak. Note that when checking, you need to hold the tip of the red measuring stick, hold the black tip of the stick and stand barefoot on the ground for highly accurate measurement.  

Next, check for electrical leakage inside the components that generate the welding pulse, such as the IGBT or Mosfet. Typically, electrical leakage can be traced to a faulty or damaged shell liner.  

Welding machines with electric leakage are very dangerous. If leakage current appears on the surface of the device, the user is at risk of shock, even life-threatening. Therefore, more and more people prioritize choosing electronic welding machines with anti-shock features to ensure safety when working..  

The electronic welding machine is weak

The phenomenon of a weak welding machine can come from many different causes. Below are common cases and appropriate solutions:  

Welding current has not been adjusted properly

This is the most common reason why the welding machine does not work effectively. Check and increase the welding current to match the type of material you are welding.  

The input wire is too small 

If the wire size is not large enough, it will affect the power supply. Please replace it with a wire with a larger cross-section, for example, 1mm² copper wire can handle about 5A..  

Poor electrical contact

Check all electrical connections from source to welding machine. Make sure the bolts are tightened so that the current flows stably.  

The distance between the welding machine and the power source is too far 

Pulling the welding machine away from the power source or circuit breaker can cause voltage drops on the line. When the distance exceeds 15m, use conductors with larger cross-sections to limit voltage drop.  

Weak power source 

A weak power source will reduce the welding machine's performance, leading to unsatisfactory welds such as convex, shallow, or narrow weld seams. In this case:  

- Increase welding current to optimal level to improve performance.  

- If the power source still does not respond, you should consider using a welding machine with weak power support technology.  

Solution suggestion: Hong Ky welding machine is designed to operate stably even when the voltage fluctuates ±15%. In addition, the machine also has an automatic shut-off mechanism when the power source is too weak, helping to protect the device and prolong its life.  

Other common errors of electronic welding machines and how to fix them  

Why do welding sparks shoot out so much?  

The phenomenon of welding sparks often occurs when the welding current intensity is set too high, leading to a wider weld line than necessary. To fix it, you need to reduce the welding current to a balanced level, based on the diameter of the welding rod and the type of electrode being used.  

For example, with stick welding, experts recommend using the adjusted formula: each 1Amp corresponds to 0.0254mm of welding rod diameter. Proper adjustment will help reduce sparks and ensure a more beautiful and safer weld.  

Welding machine makes loud noise, how to handle it? 

If the welding machine makes an unusually loud noise, the cause may be due to loose bolts. Check and tighten bolt connections. In case the buzzing noise continues without finding a clear cause, it is best to take the device to a reputable warranty or repair center for a thorough examination..  

Electrical connections get hot and blackened

This error often occurs because the contact points are not tightened, causing heat to heat up or burn the connections. To process:  

- Use sandpaper to clean the burned black area.  

- Tighten the connections with bolts.  

- If the connection is seriously damaged, contact the warranty center to replace the component.  

Conclude:

Through the above information, we hope that you have determined the cause of the welding machine problem and found a suitable solution. However, the most sincere advice is that when you encounter complex or unknown errors, you should bring your device to a reputable repair center or genuine warranty place to be checked and handled properly.