Blown my welder up.

[Retired]

Hi,

So much to learn but at the moment I'd be happy just to blow holes in metal with my welder.

I'm pleased to learn you like your Parweld XTT 202P northwest and I hope to like mine if I can get the thing to work. I'm currently exercising lots of patience but I'll stick with it. Waiting for capacitors; waiting for oven element; waiting for roller blinds; surely something will finally go my way this week but I can dream on.

Kind regards, Colin.

 

[slim_boy_fat]

Waiting for capacitors; waiting for oven element; waiting for roller blinds; surely something will finally go my way this week but I can dream on.

At least we're not 'Waiting for Godot'

 

[Retired]

Hi,

How true slim but I'm always waiting for one thing or another.

I ordered the capacitors online Saturday morning from Farnell's and already they are in Dewsbury nearby out for delivery so perhaps I'll have my hands on them shortly; I like Farnell's.

Out of interest and just one of the reasons I'm forever busy especially in warmer weather our gardens and bungalow are high maintenance demanding constant work to keep them in good order; our site is on a steep valley side making just walking up the rear garden challenging but at times I drag up the petrol mower and petrol rotavator giving me a good workout. Below is just a snapshot of what keeps me busy.

Kind regards, Colin.

Our front garden in all its glory.

Two years ago these laurels were 30' tall so I attacked them with my chainsaw at least I can now talk to them; these are just a few of our laurels which have been going ballistic this year needing constant trimming; at the very top of the mountain we have a 60' long hedge of them which I trim both sides and top.

A shot towards the bungalow; it's not bad now but I've felled and disposed of many trees including two huge 80' tall conifers and a 90' long x 8' tall conifer hedge; in front of the laurels at the top of the mountain we also had a 60' long hedge of snowberry; brambles; mile a minute vine and holly to name a few.

Another shot of the garden showing the wildflower meadow I created to replace a big hedge and grass; the weather has battered the flowers which were breathtaking a couple of months ago.

Constant fight with a family of badgers; found this hole just now and have filled it back in.

Dug over by spade to remove roots and stones; at the top was a 60' long hedge which I completely removed including stumps it being hard graft. Only then could I rotavate.

A close up of the new wildflowers at their best before the dire weather attacked them.

One of two garden huts I've made. One of the 80' tall conifer stumps can be seen to the right.

So although I moan at least I'm not idle and hopefully the pictures will be of interest demonstrating what I'm on about saying in retirement I have little workshop time; I'm into lots of other stuff too like upgrading our bungalow; the only thing I don't do is play with central heating.

We like coffered ceilings so I made and installed one.

Front room makeover I did; the fireplace surround; hearth and fire were professionally installed due to gas regulations but I did the rest including making and installing the wooden mantle around the fire. Here it's nearing completion.

Sorry I'm fftopic: but all this work takes so much of my time; I'm on gardening; DIY; vintage radio and machinist forums too. There aren't enough hours in a day. Fingers crossed I can pick up on welder once the caps arrive.

 

[minimutly]

@Hood - you don't get it do you - all this pressing - or is it tapping, has me thinking about something other than good hand movement, access, safety etc.
With a pedal all these are given priority - I don't even need to decide what amps the repair needs - my eyes tell me as soon as the pool forms.
Maybe it's just my poor short term memory, but that's me. I do promise to practice with 4t (i've used 2t quite successfully in the past), and yes I can see the advantage of not needing to press a pedal.
All good info though, and much appreciated.

 

[Retired]

Hi,

The caps arrived at 1.05pm today so brilliant service once again from Farnell.

After dinner I was keen to install the caps and spent time making a decent job. I've just knocked off after powering the welder up and it looked and sounded OK;

I thought I'd cracked it and was going to let it run for an hour or so but after a few minutes there was a loud click as the mcb tripped; oh what fun I have. So 6 expensive new caps installed and it still sulks; enough for today but I'll pull the covers off again tomorrow to have a look to see if something else shows distress; I feel its something on this power board at fault because although everything was hooked up I hadn't tried welding. The only pulse is mine at the moment and its running normal; it takes more than a set back to upset me.

Perhaps when the oven element arrives this too will be more hassle as I install it.

Kind regards, Colin.

 

[Lazurus]

Some people are so patient, that would have been hurled to save my blood pressure if it was mine

 

[Retired]

Hi,

Thanks Lazurus you've cheered me up. I'm getting experienced at removing this circuit board in fact this time it took all of five minutes to pull it out leaving the heat sink in position in the welder. The caps haven't blown this time but one of the middle caps has a slight dome now indicating some other fault stressing it. I've just emailed Parweld asking if they can supply a new circuit board the number on mine being 8.066.527-D and if so how much; if not do I have to go through one of their dealers and I gave Huddersfield as my address?

I have a nice sledgehammer Lazurus as a last resort. There's a company based locally in Wakefield that does welder repairs so I've got options yet. The two caps which blew are on the same track but I can't make out how they are connected; a proper circuit diagram would help but I'll also have a look at the circuit diagrams kindly supplied by R Kraft & Seadog in earlier posts; yes I'm paying attention to all the information and advice I'm being generously given.

At the moment I'm not a Parweld welder fan.

Kind regards, Colin.

 

[TigTigger]

If the MCB tripped this would suggest a large current was being drawn downstream from the capacitors, either on the power board itself, where there seem to be some power transistors or downstream of the power board. This would have resulted in a large ripple current which is the only thing I can think of that would stress the capacitors so quickly, since with new capacitors they are only going to be stressed/damaged through over voltage, excess ripple current or ac voltage. Sadly, unless you have a faulty bridge rectifier passing ac I would assume there is a very low resistance path somewhere. If it is the same capacitor pair that are showing signs of stress that at least should help to narrow down the faulty area. Might be worth tracing the circuit of the power board, particularly to see what the transistors do.

 

[John of Arc]

Have been following this saga for a few days and when you said that other equipment had gone belly up, it reminded me of a problem I had. My big compressor was running continuously and I noticed the motor speed changed up and down a bit. Then the cap failed. I put in a new one and that failed fairly soon. I got a very good new 4HP motor and put that in. That cap soon failed. Then later the microwave and kettle seemed to be playing up, so I checked the mains voltage, it was either 400 or 100 or so varying all over the place. It turned out to be a failing neutral connection on the power lines down the lane. Check yours!

 

[Retired]

Hi,

Many thanks TigTigger; what you say makes a lot of sense and on the same lines as I was thinking. I used to get lots of similar problems whilst restoring vintage radios but then I always had the correct wiring circuit diagram allowing me to easily follow what connected to what. There aren't that many components on the board; I tested both rectifiers and obtained perfect readings using my DMM; only one side appears at fault because the two blown caps are connected? I don't want to start doubting my rectifier test but then I've only done this static and not dynamically under load; of the six caps in two lines of three only one of the lines is at fault; I had hoped it was just bad caps at fault. Something is drawing excess current and it might not even be a power board fault; it's so easy to jump to conclusions and be totally wrong; for these new industrial caps to behave like the original caps then obviously it's not a capacitor fault at all. I can't power up as it is to take voltage readings because it's tripping the mcb; I don't want to spend forever chasing my tail so perhaps time to simply install a new board and let a repairer do it with correct testing facilities; I'm not expecting much by way of help from Parweld regarding my email enquiry but then I do need to be fair and give Parweld a chance. I could get very interested in solving this problem but I've got so many other things to occupy my time; locating the faulty component is the hard part but the nature of the fault seems to halve the circuit as a start?

I do however openly apologize to Jianghai for wrongly assuming it was their capacitors at fault assuming the short shelf life of 1000H to be involved so I retract calling their capacitors as poor and I should know better without proof.

I've not actually sat down with board and DMM to run basic tests.

Thanks for your suggestion John of Arc; I can easily run mains voltage tests. Our bungalow electrics were strange; the bathroom fan heater connected to the cooker circuit; the two roomed rear extension connected directly to the CU with a single 2.5mm T&E on a 30A mcb? The kitchen had five assorted power sockets running from three different circuits. I bought a signal tracer and now we have a ring power circuit to the main bungalow and ring power circuit to the kitchen & bathroom; I installed a new 16 way metal clad CU adding a pair of 32A "C" type mcb's to run big machines in the workshop; all the wires inside the CU I double insulated; I used my 1,000v Evershed & Vignoles Megger for resistance leakage tests so now as far as the bungalow everything is fine. The signal tracer was a huge help in sorting out where all the cables ran. I will check the mains voltage though as it's so easy to do although everything seems to be working as it should other than the oven that's worked for 22 years and the bathroom fan heater which might just need defluffing?

As an apprentice mechanical engineer I completed a six month training course in record time and then I was allowed to drift over to the apprentice electricians where I quickly learned how to connect up big industrial three phase motors to the test panel and to learn electrical safety although since then 55 years ago I've done lots of electrical work around home and the workshop. On the course I ended up just doing mornings then was quietly allowed home at dinner time.

I used to have lots of kit like Advance signal generators and scopes etc; I still have a scope but I don't have the time I'd like to spend time in the workshop.

I bought one of these;

https://www.tester.co.uk/kewtech-loopcheck-107-socket-tester

Kind regards, Colin.

 

[TigTigger]

We had the neutral problem on the main supply cable a few years ago. Did a lot of damage, particularly computers, refrigerators and freezers. Although everyone affected had their appliances repaired or replaced free of charge, including rumour has it some that just wanted a new one!!

 

[TigTigger]

The 1000 hour shelf life has to be taken in context. It refers to 1000 hours when stored at 105 degrees centigrade!! When stored at more normal temperatures 25 -30 deg C shelf life is several years at least and can be much longer.

 

[Retired]

Hi,

I've just emailed;

http://www.wakefieldweldingcentre.co.uk/service-2/

Asking for a repair rough estimate or to pop over with the welder for them to have a look at; I've already spent too much time with this problem so time it was put to bed?

Kind regards, Colin.

 

[Hood]

@Hood - you don't get it do you - all this pressing - or is it tapping, has me thinking about something other than good hand movement, access, safety etc.
With a pedal all these are given priority - I don't even need to decide what amps the repair needs - my eyes tell me as soon as the pool forms.
Maybe it's just my poor short term memory, but that's me. I do promise to practice with 4t (i've used 2t quite successfully in the past), and yes I can see the advantage of not needing to press a pedal.
All good info though, and much appreciated.

I do get it, you will get used to it within minutes and never even think about it in exactly the same way as you do not now think about the pedal but initially you would have had to think about it.
Every one to their own.

 

[Hood]

Colin, you would have been better phoning Parweld, emailing is a waste of time.
It is a shame the caps didn't fix it but hopefully either you or someone else will be able to find the issue and with a bit of luck it is relatively cheap.

 

[Munkul]

I was looking forward to seeing you get this fixed and on with welding, unfortunately not it seems

Fingers crossed the welding centre will be able to help you out. I find that a shop's willingness to fix things depends largely on the skill of that one technician whos been there since forever and knows pretty much all there is to know... if they have that guy, well and good, if they don't, then they will probably turn you away.

If you get no joy, might I suggest trying further afield - Express Cutting & Welding in Preston have one of these "guys" and if he says he can't or won't fix it, then probably no-one can.

 

[Retired]

Hi,

Thanks Hood for your suggestion. I seldom use our phone having had five phones on my three desks at work plus a pager all driving me mad for many years; I prefer email then whatever information both ways is recorded unlike using a phone when the information can be lost as soon as the phone is put down.

Thanks Munkul; I understand and agree with what you say; Jim at the welding center was in touch very early this morning by email saying he'll look into it and get back to me tomorrow. I'll bear in mind the Preston details.

Amazingly though I also received a most welcome reply by email from Parweld who have supplied lots of information including kindly sending me a schematic; I'm further asked for more details regarding the identity of the board but unfortunately I'm unable to open a lot of the detail due to Windows Media player wanting updating? I've been running the update download for well over an hour and now it appears frozen at 99%; so near and again so far but an improvement on the start to the day when "No Internet Connection" greeted me again.

Good news though the oven element arrived rapidly from "espares" and within five minutes our cooker was back in action. Now I need to sort out how to open the information kindly sent by Parweld; I think I've mentioned a few times I have lots of bad luck well at least this isn't faltering in any way and I'm battling on.

Kind regards, Colin.

 

[Hood]

I too prefer email, it is just some places do not respond to email and Parweld was one that ignored several of mine in the past. What I usually do is call places like that then say give me your email and I will send my enquiry that way, usually they respond then and you have a record.

Looks like you have struck gold though, excellent news regarding the schematic, fingers crossed you get things sorted.

 

[Retired]

Hi,

Thanks everyone for sticking with me in these troubled times.

I felt very emotional this morning after all the hassles I've suffered regarding this welder.

I was delighted to receive the email reply from Parweld supplying information and asking for more details of the power circuit board; I went down to the workshop and took note of all the board details and returned to my computer to forward the details to Parweld when I noticed another email had arrived from Jim at Wakefield Welding Centre asking me to please phone him which I immediately did.

WOW; WOW & WOW; good job I was sitting down; Jim had been in touch with Parweld upon my behalf and I'm truly amazed; Parweld have agreed with Jim to repair my welder under warranty; I filled up with emotion at this it being totally unexpected.

TOP MARKS TO JIM AT WAKEFIELD WELDING CENTRE AND ALL BEING WELL UPON THE RETURN OF THE WELDER IN WORKING ORDER TOP MARKS TO PARWELD TOO.

I've been dogged by bad luck for so long for my luck to suddenly change for the better like this is amazing. Bron and I have always worked hard to achieve what we have with absolutely no outside help; when I checked Parweld and found their warranty wasn't transferrable I just put it down to my continuing bad luck hence I didn't argue I just set about repairs myself as shown in this thread; we don't want anything for nothing and have never been scroungers. The welder shouldn't have blown up but it did and such things do happen which I accepted with good grace.

So all in all an excellent day so far today; my welder is to be repaired under warranty and the oven is up and running again; for once I've a big smile on my face and hope my bad luck is finally drawing to a close.

Kind regards, Colin.

 

[eSCHEn]

If anyone was due some good luck/karma then it surely was you Colin

An excellent result