Gys 4000 DIY repair

In detail: gys 4000 do-it-yourself repair from a real master for the site my.housecope.com.

A brief description of the cause of the failure, and a description of the replaced components of the GYS welding machine model Inverter 4000 / Gysmi 161 /
it is one and the same device, only in green color specially for sales within the LeroyMerlinVostok chain of stores.

The main reason is the bare junction between the radiator, on which the power elements are located - diodes, transistors (and probably something else) and the control board.
Burnt out PWM - 100 kHz controller.
And the power resistor fell apart (I assume destruction from overheating).
The circuits are found on the global network.
For this device, the circuit completely coincides with the GYSmi 161.
The necessary element was found according to the circuit - it turned out to be an NCP1055 / element and a 47 Ohm resistor. I picked up the resistor in terms of power - in size (I don't know for sure, but it should fit and not affect the work)

The cost of the resistor is 10 rubles. PWM controller 100 rubles.
The repair was done on our own. True, my hands came to the repair only after almost a year () at this time I used another device, however, I continue to use it to this day.

The device passed the test after the repair. He ignites the arc. Keeps it stable. Although I tried to cook without a mask, so for testing.

This problem area was protected with a silicone sealant. In case - it can be deleted, but I think this will not happen.

This problematic place is most likely on all apartments of this brand.
Therefore, you should either constantly blow it with compressed air, or protect the place from the beginning.

Conductive dust adhered to these bare conductors of the problem area - the apparatus was standing next to the grinding machine. I think this is the main reason for the combustion of the PWM and the resistor.
Or their current has increased. or a short circuit on these conductors somehow affected.

Video (click to play).

Be careful with such devices

I wish you good luck with your own repairs.

Video Repair of the welding machine GYS Inverter 4000 GYSMI 161 part 1 Reason for the failure of the AEA341 channel

The device passed the test after the repair. He ignites the arc. Keeps it stable. Although I tried to cook without a mask, so for testing.

This problem area was protected with a silicone sealant. In case - it can be deleted, but I think this will not happen.

This problematic place is most likely on all apartments of this brand.
Therefore, you should either constantly blow it with compressed air, or protect the place from the beginning.

Conductive dust adhered to these bare conductors of the problem area - the device was standing next to the grinding machine. I think this is the main reason for the combustion of the PWM and the resistor.
Or their current has increased.or a short circuit on these conductors somehow affected.

The same device began to beep when plugged into the network and a few seconds after it was turned off, during operation, the squeak is almost inaudible, it cooks perfectly. Is it worth getting into it, or not? And what to look at?

squeak is normal. capacitors are charged. if you remove the plug, there will be no squeak.

says one that it squeaks a little trance because of something there.

Hello. On the Gysmi 161, the diode at the output burned out, replaced all 4 diodes, but now it cooks only at the maximum current and is not regulated. As they advise on the Internet - to catch up before the thermal protection is triggered, after triggering it should be calibrated - it did not help. Have you faced a similar problem? Thank you

no. look at processors. all schematics on the Internet. analogue of gisemi.

O Great Sen-sei, please tell me what are the names of these elements at face value 2a, which you indicated, which burn out? I gave the same welding to one to use it ((I don’t know what he did with it, I cooked everything myself for 2 years, nothing happened. and what they should be at par. Thanks for the early 😉

+ Mitya Nushtai quote from the description under the video: The necessary element was found according to the diagram - it turned out to be an NCP1055 / element and a 47 Ohm resistor. the resistor was set with a capacity of 1 or 3 watts. in radio stores, ask. on the Internet, the wrong thing may come, and it is better to buy in the store because of the speed and advice of sellers. PWM controller burned out. and the resistor burned out. dug up schemes in the network.

How do you get the power section off the main board?

+ rati inter by heating. only I didn’t do it.

My friend, are you sure that one of the burned-out PWM element is the controller? It seems to me that this is a transit. not?

+ andrey lozhkin there is an ncp105x microcircuit, here is a datasheet for a series:

+ Andrey Lozhkin, according to the schematic diagram, is a microcircuit - and not an ordinary transistor. 100 kHz PWM controller. I bought a spare part in two stores: I also asked - one had the same microcircuit, and the other had other legs, but this is definitely a PWM controller. the sellers are knowledgeable, in the diagram this is a PWM controller, it does not have a radiator, there are four pins.

Read also: Lukey 852ad DIY repair

Excessive power consumption, even when the device is not loaded, most often causes turn-to-turn closure in one of the transformers. In this case, you will not be able to repair them yourself. It is necessary to take the transformer to the master for rewinding.

This happens if the voltage drops in the network... To get rid of the sticking of the electrode to the parts to be welded, you will need to correctly select and set up the welding mode (according to the instructions for the device). Also, the voltage in the network may sag if the device is connected to an extension cord with a small wire cross-section (less than 2.5 mm 2).

It is not uncommon for a voltage drop that causes the electrode to stick when using a power strip that is too long. In this case, the problem is solved by connecting the inverter to the generator.

If the indicator is on, this indicates overheating of the main modules of the unit. Also, the device can turn off spontaneously, which indicates tripping of thermal protection... So that these interruptions in the operation of the unit do not occur in the future, again, it is necessary to adhere to the correct mode of the duration of the on (DC). For example, if duty cycle = 70%, then the device should work in the following mode: after 7 minutes of operation, the unit will have 3 minutes to cool down.

In fact, there can be a lot of various breakdowns and the reasons that cause them, and it is difficult to list them all. Therefore, it is better to immediately understand what algorithm is used to diagnose the welding inverter in search of faults.You can find out how the device is diagnosed by watching the following training video.

Repair of welding inverters, despite its complexity, in most cases can be done independently. And if you are well versed in the design of such devices and have an idea of what is more likely to fail in them, you can successfully optimize the costs of professional service.

Replacement of radio components in the process of repairing a welding inverter

The main purpose of any inverter is to generate a constant welding current, which is obtained by rectifying a high-frequency alternating current. The use of a high-frequency alternating current, converted by means of a special inverter module from a rectified mains supply, is due to the fact that the strength of such a current can be effectively increased to the required value using a compact transformer. It is this principle underlying the operation of the inverter that allows such equipment to have compact dimensions with high efficiency.

Functional diagram of the welding inverter

The welding inverter circuit, which determines its technical characteristics, includes the following main elements:

a primary rectifier unit, the basis of which is a diode bridge (the task of such a unit is to rectify an alternating current coming from a standard electrical network);
an inverter unit, the main element of which is a transistor assembly (it is with the help of this unit that the direct current supplied to its input is converted into an alternating current, the frequency of which is 50–100 kHz);
a high-frequency step-down transformer, on which, due to a decrease in the input voltage, the output current is significantly increased (due to the principle of high-frequency transformation, a current can be generated at the output of such a device, the strength of which reaches 200–250 A);
output rectifier, assembled on the basis of power diodes (the task of this block of the inverter includes rectifying an alternating high-frequency current, which is necessary for performing welding).

The welding inverter circuit contains a number of other elements that improve its operation and functionality, but the main ones are the above.

Repair of an inverter-type welding machine has a number of features, which is explained by the complexity of the design of such a device. Any inverter, unlike other types of welding machines, is electronic, which requires the specialists involved in its maintenance and repair to have at least basic radio engineering knowledge, as well as skills in handling various measuring instruments - a voltmeter, digital multimeter, oscilloscope, etc. ...In the process of maintenance and repair, the elements that make up the welding inverter circuit are checked. This includes transistors, diodes, resistors, zener diodes, transformer and choke devices. The peculiarity of the design of the inverter is that very often during its repair it is impossible or very difficult to determine the failure of which particular element was the cause of the malfunction.A sign of a burnt out resistor may be a small carbon deposit on the board, which is difficult to distinguish with an inexperienced eye.In such situations, all the details are checked sequentially. To successfully solve such a problem, it is necessary not only to be able to use measuring instruments, but also to be quite familiar with electronic circuits. If you do not have such skills and knowledge at least at the initial level, then repairing a welding inverter with your own hands can lead to even more serious damage.Realistically assessing their strengths, knowledge and experience and deciding to undertake independent repair of inverter-type equipment, it is important not only to watch a training video on this topic, but also to carefully study the instructions, in which manufacturers list the most typical malfunctions of welding inverters, as well as ways to eliminate them.

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The problem is as follows. I plug the device into the network, turn on the device itself, absolutely nothing happens. no signs of serviceability) I disassemble, visually I see that the transistor indicated in the figure in red has burned out. before that, some craftsmen were shamanizing something in it, it can be seen that they were soldering the trance taps of the same strapping, and the resistor tap, well, okay, took the transistor a little more powerful in terms of parameters, soldered it, when the device was turned off, when it was turned on to the network immediately this the transistor burns out before our eyes. I found the circuit on 161 and 165, but according to the arrangement of the elements, none of them fit my board. model 161, but the board is similar to model 165. before that the inverter worked properly. Please help me raise it, I'm sorry for the device.

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Turn off the fan and ring it. Perhaps he is short. Apparently, this is the same fan power circuit. And call the diode D11S01.
And in general, turn off this transistor and turn it on without it and the fan, to begin with.

Post has been edited DANTIST – 12.5.2014, 16:10

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On Volodin's website, in the topic of repairing IN, I laid out a diagram and pictures of how to replace NCP with TOP224. The alteration is simple.

Post has been edited VrnAlexM – 12.5.2014, 21:50

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Well, I immediately dropped it. checked all the harness. actually pages 5 and 6 of the datasheet, all elements are intact. I'll try to turn it on today without a valve and a soldered mikruhi.

although with a burnt native mikruha I turned on, zero reaction.

Well, of course there is, I am always glad to have good advice from an experienced specialist.

I did not check the output. the bridge was ringing, intact, the sandwich had not yet been disassembled, but the bolts had already been ripped off. judging by the bolts, the previous repair was not in the power section, they just soldered the piping where the burned mikruha was, namely, the lower right trance taps TR51X01 were soldered in the footsteps, the R41P21 was soldered off, and either they changed or simply blew off the Q41P01.

regarding repair, let's say I have a tool and experience in soldering, including smd. the inverter, let's say, was presented as a non-worker, or rather, he asked for it himself for restoration and home use. the costs have already gone, I have already bought 2 transistors, one of which I burned, and just sports interest and new knowledge will not interfere.

about sharing spare parts. I'm from Donetsk))))

guys, thank you all for the advice, I will try. when you start throwing, it’s not good.

Video (click to play).

Post has been edited passlight – 13.5.2014, 12:32

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