How to Solve Electrical Module Abnormalities in Mid-Frequency Spot Welding Machines?

During the use of mid-frequency spot welding machines, electrical modules may encounter issues such as module alarms reaching the limit and welding current exceeding the limit. These problems can hinder machine usage and disrupt production. Below, we’ll detail how to address these issues:

Module Alarms Reaching the Limit:

IGBT module experiences overcurrent: If the transformer power is large and not fully compatible with the controller, please replace the controller with a higher power rating or reduce the welding current parameters.

Secondary diode of the welding transformer is short-circuited: If the secondary circuit is open, use a multimeter to measure the secondary diode. If one measurement indicates normal conductivity and the other does not, the diode is damaged and needs replacement.

IGBT module damage: Disconnect the drive line and measure the resistance between the IGBT module’s GE. Resistance above 8K ohms indicates normal functionality, while lower resistance indicates damage, necessitating module replacement.

Damage to the IGBT module driver board: Replace the IGBT module driver board.

Damage to the main control board: Replace the main control board.

Welding Current Exceeding the Limit:

Welding current exceeds the set upper and lower limits: Adjust the maximum and minimum current parameters in the specification settings.

Preheating time, ramp-up time, set values exist: For general use, set preheating time, ramp-up time, and ramp-down time to zero to avoid frequent current limit alarms.

Welding current setting value is too small: For general use, set the welding current value to at least 10% to avoid current limit alarms.

Pre-pressure time is too short: If the pre-pressure time is too short, the electrode starts welding as soon as it presses against the workpiece, causing the current transformer to not sense the welding current and trigger an alarm. Increase the pre-pressure time.

Electrode stroke is too long or not clamping the workpiece: Place a thin piece of paper between the electrodes. When the electrode presses down, if the paper tears, the stroke is appropriate; otherwise, it’s too long and needs adjustment.

Current transformer wire breakage or looseness: Check the connections of the current transformer for wire breaks or loose plugs.

Suzhou Agera Automation Equipment Co., Ltd. specializes in the development of automated assembly, welding, testing equipment, and production lines, serving industries such as household appliances, automotive manufacturing, sheet metal, and 3C electronics. We offer customized welding machines and automated welding equipment tailored to customer needs, including assembly welding production lines, assembly lines, etc., providing suitable automation solutions for enterprise transformation and upgrading. If you are interested in our automation equipment and production lines, please contact us: leo@agerawelder.com