Welder Breakdown Repairs & Electrical Fault Finding

Erratic wire feeding is commonly caused by a worn wire speed potentiometer on the front panel, a failing transistor on the DC motor drive board, slipping mechanical drive tension rolls, or a damaged torch trigger control lead. We test the DC voltage output to the wire drive motor under load to determine whether the issue is electrical control or mechanical drag.

High-frequency arc ignition relies on a dedicated high-voltage circuit and an internal spark-gap assembly. If the tungsten spark gap points become oxidised or worn out of tolerance, or the high-frequency bypass capacitor breaks down, the HF spark will fail, forcing the operator to scratch-start. We clean, gap, and test HF ignition circuits.

Premature thermal tripping usually occurs because cooling fan blades are seized or jammed with grinding dust, internal heatsink fins are clogged with metal swarf, or the internal bimetallic thermal sensor has drifted out of calibration. We clean internal cooling passages and test thermal cut-out switches.

Yes, we troubleshoot and repair electrical power supplies, wire feeders, and control gear across standard manual fabrication welders through to heavy automated submerged-arc and robotic welding power sources.