I. Ensure Good Heat Dissipation and Control Temperature from the Source
1. Maintain Good Ventilation: The electrofusion welding machine should be placed in a well-ventilated, dry, and unobstructed area, with at least 30cm of space around it to ensure smooth airflow.
2. Clean the Cooling System Regularly: Use compressed air to clean dust from the cooling fan, vents, and power modules to prevent blockages that could affect heat dissipation efficiency.
3. Check Fan Operation: Before each startup, confirm that the cooling fan is running normally. If abnormal speed or shutdown is found, replace it immediately.
II. Arrange Work Schedules Reasonably to Avoid Heat Accumulation
1. Follow Duty Cycle: Most electrofusion welding machines are designed for intermittent operation (e.g., 60% duty cycle). It is recommended to stop the machine for 10-15 minutes to allow internal components to dissipate heat after every 3-5 consecutive welding sessions.
2. Avoid Prolonged Operation in High-Temperature Environments: In summer or when working in enclosed spaces, use an external fan for auxiliary cooling, or weld in batches to reduce the rate of temperature rise. III. Optimize Power Supply and Connections to Reduce Additional Heat Generation
1. Use Power Cords with Appropriate Cross-Sections
It is recommended to use copper core cables with a cross-section of ≥4mm² to reduce voltage drop and prevent overheating caused by insufficient voltage leading to high current draw in the welding machine.
2. Ensure Secure and Oxidation-Free Wiring
Output terminals and copper cap contact surfaces should be secure and free of rust, with a contact resistance ≤0.01Ω to prevent localized overheating.
3. Match Stable Power Supply
If using a generator, its rated power should be at least 1.5 times the welding machine's power to ensure stable output voltage and prevent overheating caused by fluctuations.
IV. Strengthen Daily Maintenance and Condition Monitoring
1. Regularly Inspect Internal Components
Inspect rectifier modules, capacitors, etc., for discoloration, bulging, or burn marks, and replace aging components promptly.
2. Monitor Operating Temperature
Use an infrared thermometer to regularly check key components such as the transformer casing (≤75℃) and heat sinks (≤85℃). If any abnormalities are found, immediately shut down the machine.
3. Replace with high-performance cooling components. Upgrade the ordinary cooling fan to a fan with a booster function, increasing airflow several times and significantly improving heat dissipation.
V. Rely on and verify the effectiveness of protection mechanisms.
1. Enable overheat protection function. Ensure the welding machine's "OH" (Over Heat) protection is not disabled and can automatically shut down and alarm when the temperature exceeds the limit.
2. Regularly test protection response. Verify its reliability by simulating continuous operation and observing whether overheat protection is triggered.
