I. Thoroughly clean the cooling system to restore heat conduction efficiency
1. Blow away internal dust: Use dry compressed air to thoroughly clean the cooling fan, ventilation holes, rectifier module, transformer casing, etc., to prevent dust accumulation from affecting heat dissipation.
2. Check fan operation: Confirm that the fan rotates smoothly without abnormal noise, and that the power supply line is not loose; if abnormal speed or stoppage is found, replace it immediately.
3. Special maintenance for water-cooled models: Check if the coolant is sufficient and whether it has deteriorated, and whether the pipes are aging or blocked. Replace the coolant and clean the circulation system if necessary.
II. Inspect key electronic components to eliminate potential damage
1. Visual inspection: Open the casing (after power is off) and check the rectifier bridge, IGBT module, filter capacitors, etc. for discoloration, bulging, or burning marks.
2. Instrument Testing
Use a multimeter to check for power components that are short-circuited or broken down.
Use a megohmmeter to measure the insulation resistance between the input and the casing; it should be ≥1MΩ to prevent leakage risk.
3. Replace Aging Components
If bulging capacitors, dried thermal paste, or aging connecting wires are found, replace them to avoid secondary faults.
III. Verify the Protection Function's Normal Response
1. Check Fault Records
Check if the control panel displays an "OH" (Over Heat) alarm to confirm that overheat protection has been triggered.
2. Test Protection Reset
After restarting, observe whether the alarm can be cleared manually or automatically to ensure that the protection mechanism is not disabled.
3. Simulated Temperature Rise Test (Professional Operation)
Continuously run the welding machine and observe whether the protection is triggered again at high temperatures to verify its reliability.
IV. Optimize Connections and Power Supply to Reduce Additional Heat Sources
1. Check Output Wiring
Ensure that the electrode posts and copper caps are securely fastened and free of oxidation, with a contact resistance ≤0.01Ω to prevent localized overheating.
2. Replace with qualified power cord. Use copper core cable ≥4mm² to avoid excessive voltage drop and overheating caused by excessive current from the welding machine due to thinner wire diameter.
3. Independent power supply circuit. Avoid sharing circuits with high-power equipment to ensure voltage stability and reduce the risk of overload.
V. Adjust work habits to prevent heat accumulation.
Follow the duty cycle: For example, at 60% load, it is recommended to stop the machine for cooling for 10-15 minutes after every 3-5 welding sessions.
Avoid continuous operation in high-temperature environments: When working in summer or in confined spaces, an external fan can be installed for auxiliary cooling.
Establish a daily inspection system: Check the fan, temperature, and wiring status before and after each use, and address any issues promptly.
