ESAB Smash welder (MIG) wire feed problem

[mjnurney]

i have a well battered but working (was) esab welding set, however after using this set for an hour or two the wire feed became eratic and has now stopped working.

The wire feed now turns very slowly or not at all or turns quickly then stops.

ive stripped the wire feed motor and gearbox and all looks well. The problem seems to be the voltage as it starts from about 14v the drops to 1v after 3 or 4 seconds.

any ideas guys?

One capacitor 250v 0.1uf (foil) has blown next to a large capacitor and i will change that but i doubt thats the fault...

cheers
mike

Esab smashweld 180

[OldSkull]

Apparently this machine got 3 transistors for the drive in parallel and one for the brake of the motor. Check the condition of all 3 transistors .
Link for the parts list and manual http://manuals.esab.com/_private/Lib...f?noCache=7055

Test transistor M13,1 M13,2 and M13,3 .Wish this help.

[mjnurney]

thanks i will try these :-)

mike

[mjnurney]

The controller board has 4x 250v 0.1uf foil capacitors , these have all failed (cracked in half) i have replaced them and now i have 15v at the wire the fire feed that still drops to 0v after 10 seconds or so. im waiting for 4x new transistors to arrive in the post...

mike.

[mjnurney]

After refitting the wirefeed unit and bolting everything back , the wire voltage is 15v and runs perfectly now for some bizzare reason !

maybe changing all those caps did fix it... even the spot weld function and the self adjust wire speed / power works.

thanks all.

mike

[OldSkull]

Happy ending! Well done Keep those transistors you order, this is a common problem on the Esab smash series.

[mjnurney]

well sadly its gone again , 0v at the wire motor .....
I'm beginning to think these are junk

[jontheturboguy]

Youve got a component or two that is heat / voltage sensitive because it has failed or is old.

Also, check the drive motor brushes. If they are worn or damaged they will draw excessive current.

[mjnurney]

well its not a fault with the transistors at all , I've had the PCB checked out too and thats fine.

its the ESEA EG 10 contractor that has burnt out and cracked down one side. now I've taken this off and ordered a new one.

but does any one have pics on the wiring on this as I'm unsure where the purple wire goes .... thank you :-)

[mjnurney]

Does anyone have a pic of where the wires go to the contractor on this welding set please?

i removed it in a hurry and ive forgotten where the purple wire goes (top or bottom)

[L.B]

Apologies to the op....
Rather than start a new thread,I thought Id just tack on here....
I have had basically the same problem as the op but for a 240v model (Australian market,180 Smashweld)
Oldskull or anyone please help with a 240v wiring diagram as this machine was passed onto my by an uncle that taught me how to weld,I cant throw it away.
Cheers Jason

[clackeen]

Problem in the IGT

[mjnurney]

mine smash weld is also the 240v

and its working perfectly now. the fault was the cracked relay & capacitors failing on the pcb

mike.