Super200P Capacitor Board - Blew Up

[mixmasterk]

my Super200P blew one of the 6 capacitors for some unknown reason while TIG welding. I need a replacement board under warranty ASAP. Also called and left a message yesterday before the event that the unit didn't have the long back cap for the TIG torch. Only the small one was there. The long unit wasn't in any of the packages. Need one of those as well.

Kris
Precision Composites Technologies
Arlington, WA

[UA440Fitter]

That's a real bummer.... Hope they get back with you ASAP.

FYI... They must be out of town or something. I left 2 PM's for Alex 2 days ago, and he hasn't responded back yet.

Bret

[mixmasterk]

They are there. I talked with Alex the day before. I couldn't get a hold of anyone earlier this afternoon until around 3pm; I got the operator. They're either extremely understaffed or who knows what.

Kris

[Cruizer]

Looks like 450 Vdc caps, those caps would have had to take a sustained hit of over 480 VDC to blow.

You have other problems other than the caps board, Probably a failed IGBT, I'd guess.

[EVERLAST]

Hello Guys ,, sorry i was in and out for the past couple of days .. had to attend tample with all this holidays ! please email me you tel numbers and i will get back at you asap

alex

[EVERLAST_SUPPORT]

It is also possible the cap could have just been a bad cap. I just change 8 out of a flat screen LCD display (not a welder), but they were an obvious bad batch (US company as well though the parts inside where not).

So it could be a couple things.

Either way, Alex will take care of you. With the holiday, things are running a little slow, sorry for any delays.

[down19992000]

what holiday are you referring to?

[duaneb55]

what holiday are you referring to?

Chinese New Year?

[Cruizer]

So thats whats happening....., My parts have literally dried up. Products to be built have come to a hault. Forgot all about that New Years thingy.

[Cruizer]

It is also possible the cap could have just been a bad cap. I just change 8 out of a flat screen LCD display (not a welder), but they were an obvious bad batch (US company as well though the parts inside where not).

So it could be a couple things.

Either way, Alex will take care of you. With the holiday, things are running a little slow, sorry for any delays.


True but LCD caps don't charge to 450VDC . IF you have a bad Cap, you have a bad Drain, and / or failed firing IGBT, or Mosfet. That Cap would have gone off like a grenade weakening the others.

[mixmasterk]

And believe me, it was loud. Sounded like a gun shot.

[EVERLAST]

Hello Mixmasterk

please PM me your tel number

alex

[mixmasterk]

Just talked with Alex. We are working on a resolve to the problem. This is the first Super200P that has had this problem. They had a bad batch of cut machine before that did the same thing an it was the MOSFETs. I have new caps arriving at the shop tomorrow. I'll replace the one that blew (or maybe all of them since I have 6 coming) and see what happens. I told Alex that I'd give him a call tomorrow after running with it and let him know the outcome. If it does it again, then we know that we need to service out the MOSFET unit or the unit as a whole. Either way, no problems with service. A+++

Kris Anderson
Precision Composites Technologies, LLC

[Cruizer]

Just talked with Alex. We are working on a resolve to the problem. This is the first Super200P that has had this problem. They had a bad batch of cut machine before that did the same thing an it was the MOSFETs. I have new caps arriving at the shop tomorrow. I'll replace the one that blew (or maybe all of them since I have 6 coming) and see what happens. I told Alex that I'd give him a call tomorrow after running with it and let him know the outcome. If it does it again, then we know that we need to service out the MOSFET unit or the unit as a whole. Either way, no problems with service. A+++

Kris Anderson
Precision Composites Technologies, LLC



There should be screws to install the caps, make sure they are all tightened to 25 inch/lbs.Throw some green locktite onto the threads so they don't try to back out.

Don't replace 1, replace all of them at the same time.

[mixmasterk]

There should be screws to install the caps, make sure they are all tightened to 25 inch/lbs.Throw some green locktite onto the threads so they don't try to back out.

Don't replace 1, replace all of them at the same time.

They are not the screw in type. The KMH style caps are snap-in, but soldered to the board. I plan on replacing them all due to the possibility that they may have received a massive amount of sonic shock from the one cap blowing.

I'll post results tomorrow on the outcome.

[mixmasterk]

OK guys here is the update. And it is good.....

Removed all of the 450v caps from the board and cleaned up the board. I inspected the cap that blew and took a pic of what I found. You'll notice a small wire going off to the side of the terminal on the right. I have a feeling it was crossed to the other side (with maybe a small gap in between) and shorted the cap which caused the blow. It may have been a piece of wire that accidently got in between the terminals during assembly. Either way, there would be no way to catch this during a visual QC as you would not be able to see it. I'm pretty sure the cap wasn't defective, just shorted. All of the caps, made by Nippon Chemi-Con, have been replaced with the same value caps made by Hitano. Below are more pics of the change over. The job to do the change over takes about an hour or less including removal and installation of the board.

I tested the unit first with the plasma cutter setting. The manual says set the air at 60-70 psi. It's too high. The air pressure was blowing out the arc. I dropped it to 50 psi (working pressure) and it started right away and cut just fine on 1/8" plate steel. If anyone else is having an issue with cutting, try this.

I then ran a few tests with the TIG (foot pedal for control). 2 runs using filler rod and 1 run without on 1/8" plate steel. TIG worked fine over the full amperage spectrum and penetrated all the way to the back side of the plate.

I just talked with Alex @ Everlast as well. Everything is being covered by warranty by them so I am not out anything. This definetely shows that they are willing to stand by their products and keeps their customers, whatever it takes. If only more companies tried to do the same.

[EVERLAST_SUPPORT]

We do stand by our products and we at Everlast are happy that you had the knowledge to replace the CAPs and are working fine. Saves on shipping for sure.

Glad you're happy with the unit. As far as warranty items if we owe you anything, you have to call the main number, as this forum is just support. Call in and talk to Alex he will make it right for you.

[UA440Fitter]

Good job with the repair! :drinkup: Now you just need to post some pics of those weld beads!

Bret

[Cruizer]

I'd be inclined to check the voltage going to those caps just out of curiousity. If its 440 or more, you have more concerns.

[Cruizer]

Besides if that pin was bent over like that, it wound't make the contact and take a charge, no charge and no blowy blowy

[UA440Fitter]

Besides if that pin was bent over like that, it wound't make the contact and take a charge, no charge and no blowy blowy

The "pin" isn't bent over. There is a piece of wire, looks like excess cut from another component, sitting on the terminal pin. It could have arced to the metal on the capacitor case.

Bret

[Cruizer]

I'd be more at ease on this unit if you were to take a resistance reading off those drain resistors on the bottom of the board. If they are good and show a resistance, of I'd guess 20K ohm. You'll be happy for a while, if they show "open" or infinate resistance, expect another shotgun blast.

[mixmasterk]

The "pin" isn't bent over. There is a piece of wire, looks like excess cut from another component, sitting on the terminal pin. It could have arced to the metal on the capacitor case.

Bret

Yeah, it was either that or it was in between the two terminals with a small, hairline gap. It doesn't take much for an arc to happen, as we all know from welding anyway. The resulting "pop" with the limited air space between the cap and the board would have been enough to tweek the wire to the other side. Kind of like setting a small explosive at the meeting point of swinging double doors.

I'm not worried about it now. I used the plasma and TIG on it again later that afternoon to fab up a control rod for the jet I'm working on. Works fine, no problems. If it was going to go again, it would have while I was using the TIG extensively.