I. Equipment Abnormalities
1. Abnormal Temperature Rise
Casing temperature exceeds 60°C (burning sensation within 3 seconds when touched with the back of the hand)
Heat sink temperature exceeds 80°C (detected with an infrared thermometer)
2. Operating Status Change
Automatic thermal shutdown (when the IGBT temperature exceeds 85°C)
Abnormal increase in no-load current (normally <5A)
II. Welding Quality Abnormalities
1. Weld Defects
Defects such as porosity and lack of fusion (overheating causes unstable weld pool)
Bluish weld color (partially (Partial overheating and oxidation)
2. Abnormal welding material
Welding wire sticking to the contact tip (copper tip temperature exceeds 200°C)
Rapid oxidation of the electrode tip (normal service life shortened by more than 50%)
III. Abnormal auxiliary systems
1. Cooling system failure
Cooling water flow <5 L/min (normal should be ≥8 L/min)
Cooling fan speed decreased (below 2000 rpm)
2. Abnormal electrical parameters
Amperemeter fluctuation >10% (normal should be <5%)
Insulation resistance <2 MΩ (megohmmeter test)
