There are thousands of Repair Centers throughout North America that Service and Repair Welders. This equipment is used by Hobbyists, Farmers, and Industry professionals for both Hand and Automation applications. The Welders can be generally classified as being Transformer based, Transformer based with SCR switching, Chopper or Inverter based. High end products such as Engine Driven Welders, Synergic MIG Welders, and Plasma Welders fall into these same general categories.
Eventually, this equipment will fail and require repair. Large organizations take on in-house repairs but the majority of work occurs in privately run small businesses. Efficient Welder Service and Repair requires that the Repair Centers have a full range of Test Equipment and Welding Accessories. The following list outlines a good starting point for procurement of this Equipment:
1. Primary AC Power (Mains): 115V, 208/230V Single and 3 Phase, 460V 3 Phase.
These Voltages are used to encompass various input power requirements for multiple Welder configurations. Not all Welders run off the same Primary AC Voltage. A Welder must be tested at the same voltage as it is being used in the field. Any Welder that is capable of 460V operation must be tested at this voltage. Any Bus voltage balance problems will be noticeable only at the higher AC input voltage.
2. DVM (Digital Volt Meter) and Analog Meter.
A DVM provides great precision for all measurements. Ensure that your DVM has a Diode Test position, and is capable of measuring Capacitance. These are important features to have. An Analog Meter is also useful. It can provide a good indication of Power Supply ripple on a DC Supply through judgment of Meter needle stability.
3. Battery powered DSO (Digital Storage Oscilloscope).
Mains powered Oscilloscopes have grounded Alligator clips on the Oscilloscope Probes. I.e. the BNC outer is electrically connected to Mains ground. This can cause signal shorts when a measurement is being carried out. To avoid this problem a Mains Isolation Transformer and/or Isolated Probes will need to be used. Battery powered DSO's do not have this issue. Equipment portability is also important in a Workshop environment.
4. IGBT & MOSFET Tester or Component Analyzer.
Tests the functionality of IGBT and MOSFET switching components when a gating signal is applied. A Component Analyzer provides additional analysis of the D.U.T (Device-Under-Test) and alleviates the requirement for the Technician to know the configuration of the component leads.
5. SCR Component Analyzer.
Tests the functionality of SCR's with an applied gating signal. A Component Analyzer provides additional analysis of the D.U.T (Device-Under-Test) and alleviates the requirement for the Technician to know the configuration of the component leads.
6. Stator Winding Analyzer.
Tests the Stator Windings on Engine Driven Welders. Analyzes the windings to determine issues with continuity, and shorted turns. Can be used on both single phase and 3 phase output windings.
7. Capacitance Meter.
Invaluable for measuring the capacitance of Excitation Capacitors in Engine Driven Welders, and other equipment. Some DVM's do not include a Capacitance range.
8. ESR Meter.
Used to measure the Effective Series Resistance of Capacitors. Capacitor failures can occur at the lead bonding point. This problem can not be seen with a Capacitance Meter, but can account for internal losses. Provides a different perspective on Capacitor fault analysis.
9. AC / DC Current Clamp Meter, capable of measuring up to 1000 Amps.
Allows accurate measurement of Primary AC Power (Mains) Input current, Welder output current and Wirefeeder Motor current. Provides confirmation of Welder calibration.
10. Load Bank (Active or Passive).
Dissipates Weld output current at rates determined by adjustable resistance settings. Used to validate output current capabilities and for Burn-in testing. Active Load banks can provide variable output characteristics in real time.
11. Hi-Pot Tester or Insulation Tester.
Used to test for High Voltage leakage conditions (typically to ground).
12. Soldering Iron.
Weller makes some great offerings. Look for Soldering Stations with ESD safe housings. Having the right tips for the job is important.
13. Air Compressor. Up to 120 psi and 600 SCFH.
For general cleaning- Metal dust, and debris. Also used for Plasma Cutter operation.
14. Cylinder gases (Argon, Ar/CO2 75/25).
For Weld testing of units after Repair/Functional Test.
15. Assorted Hand tools.
Screwdrivers, Socket wrenches, Wrenches, Pliers, Hammers, Allen keys etc.
16. Torque Driver.
Most screws and bolts need to be torqued correctly to the Manufacturers specification. This is extremely important where thermal conductivity properties are important. IGBT's, MOSFET's and Hockey Puck SCR's must be correctly torqued to their Heatsink assembly.
17. Flow meter for torch testing.
Used to check gas flow rates through the torch. Important for Plasma Welding and MIG applications.
18. Coolant Conductivity Meter.
Used to test the conductivity of coolant that is used in Plasma Welding Systems. If the coolant becomes conductive this can cause the Plasma Welding Torch to become shorted. This causes permanent damage.
19. Wireless or Cell phone.
Allows the Technician to communicate to Technical Support staff (Manufacturers representatives) while troubleshooting the Welder.
20. Wirefeeder.
Used for Weld testing MIG (CV) Welders.
21. Assorted Stingers, MIG torches, TIG torches, Leads.
Most Welding Power Supplies don't come in with accessories, unless requested. These need to be available in different configurations for Weld testing the product.
22. Loading Dock with Fork Lift or Hoist.
Used to move heavy equipment in and out of the workshop.
23. Computer (Desk Top or Laptop) with Internet access.
Used to access Manufacturers sites for support inquiries, and downloading of Service Manuals. Also, preparation of Word documents, Database access etc.
24. ESD prevention materials and equipment.
Suitable lengths and quantities of Static Dissipative Matting, Wrist Straps, Foot Straps, Cords, Bonding Points, etc for setting up an EPA (ESD Protected Area). This designated area will be used for replacement of electronic components and PCA's (Printed Circuit Assemblies).
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