Diagram of a welding inverter fubag in 203 DIY repair

In detail: a diagram of a welding inverter fubag in 203 DIY repair from a real master for the site my.housecope.com.

Fubag in 203 is a professional inverter welding machine. A very popular model. Fubag in 203 comes to repair very often. The weakest place is the IMS module and the power supply. It is repaired in 1-4 hours, provided that before our SC the hands have not been in the device “all

Control board
Power section (IMS module)

Power section (IMS module) - repair
Management - repair

To fill out an application for the repair of the Fubag welding machine, please call: 8 (495) 215-17-22.

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We carry out free diagnostics within 3-4 hours and report its results in any way convenient for you.

We repair equipment, test it, provide a guarantee up to 1 year.

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On the FUBAG IR 220 welding inverter, the PWM controller burned out and the inscription on it is not visible. From various sources in the net they advised to put the UC3843 PWM in place of the burned one. I found and put the UC3843B PWM at my own risk. ... The device turned on the thread of the lamp burns in full heat, the fans started up and the relay worked. There is no smoke or light anywhere. I measured the output voltage at all. The RJH60F7 transistors rang all intact. Powerful ohm resistors are also intact. There are no circuits for this device, therefore It is difficult to figure out why there is no voltage at the output, when everything seems to be intact, so I am asking for help in this matter.

Video (click to play).

- - Here are my photos, I will immediately apologize for the quality, not a professional. And my question remains valid, why is there no +60 volt voltage at the output of the inverter?
    
    Edited by Andryzel (27.06.2016 16:51:22)
    
    The fans are spinning, the relay is triggered, everything starts smoothly, the lamp is on, the network is on, but there is no output. The power keys are all whole voltages on the conductors of almost 400 volts. It feels like there is a breakage somewhere at the output, but without a circuit I can't eat this beast. Maybe the second shim is dead. After all, I replaced UC3846 first with UC3843. Also, the zener diode burned out without a circuit, I don't know the name, it is in the base circuit of the K3878 transistor. We need a Russian analogue of a zener diode.
    - I agree. It's difficult without a diagram, but it's worth trying.
      
      Maybe the second shim is dead UC3846 because the first one I replaced UC3843. The zener diode also burned out without a circuit, I do not know the name, it is in the base circuit of the K3878 transistor. We need a Russian analogue of a zener diode.
      
      Zener diode for 18V. 1N4746A Russian analogue of КС218Ж.
      
      Let's figure it out. Fortunately, I have the same apparatus. Tell us with what malfunction it came to you, how did this malfunction occur, what have you already done?
      
      Edited by Andryzel (06/29/2016 06:42:12 PM)
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        a on L7815 +11.8 volts. It seemed a little understated
        
        It is not normal. Strongly underestimated. You are looking in the right direction and close to the answer.
        
        Today I changed the voltage regulator L7815 to an analogue of K142EN8, the voltage remained 11.8 volts. The direction seems to have chosen the wrong one. Power to the voltage regulator L7815 comes from the secondary winding of the transformer Tr2 through diodes. Power is also supplied to the fans from here. So where the fans are powered, it says +24 volts. Measure there +15.6. A big request to you, if you have the same welding worker, please measure how much voltage goes to the fans, where it is + 24V.
        
        Edited by Andryzel (07/03/2016 10:55:14 PM)
        
        Thank you for the hint. So I did, I turned on the device without a light bulb. The device started up and the output really became more + 77 volts. But my joy was not long. After driving the device for about 20 minutes at idle without load, I turned it off with a button from the mains. In general, I was 100% sure that it was possible to give the device to the owner. The device stood at work at night and in the morning I came to work and decided to check the welder again. Plugging it into the network, the device started up and soon stopped working. Having disassembled it, I began to measure the power on the UC3843B with a multimeter. The power supply showed + 7.9 volts. I think very little again, the microcircuit is out of order. I soldered the mikruhu from the board and began to check with a multimeter between the 5th and 6th legs, There is no short. Then I also measured between 5 and 7, there is also no short, then 6 and 7. In general, there is no short anywhere. Only this is not an indicator for microcircuits. But how do you know that it is intact? Then I turned on the device without a microcircuit in the network and again I measured the supply voltage of the microcircuit and was very surprised by the + 80 volt reading. I measured it on the C75 encoder (47mkfX63v), which is parallel to the microcircuit power buses. In general, I'm in a slight shock. Either the device showed it without load. Or again there is a malfunction in the microcircuit power circuit. In general, I don’t know how much + 80v should come without load. or maybe + 12V.
        
        Thank you again for helping me. I read in the net about the UC3843B about all its functions. A smart thing is this mikruha.
        In short, if, what is wrong with the diodes in the secondary circuit of the TP2 transformer, the microcircuit simply stops working and goes into protection. All the intricacies of electronics. I found the cause of all the troubles with the launch of the UC3843B was a leakage diode D25. I replaced it and everything returned to normal. The device whispered and again the joy visited me that it was not in vain.
        
        Good luck!
        Edited by Andryzel (06/29/2016 11:42:12 PM)
        
        And what is the real capacity of the C75 condenser?
        
        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 be compact in size 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).
        
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        The welding inverter circuit contains a number of other elements that improve its operation and functionality, but the main ones are the above.
        
        They brought the aforementioned device for repair. Did not turn on: the power supply attendant was dead - restored.
        The device starts up (for all adjustments, settings such as Hot start, Arc force, welding current adjustment with the “+” and “-“ buttons, switching between MMA / TIG modes - it reacts quite adequately, that is, as it should be).
        BUT - when the plug is connected to the network (without pressing the ON / OFF button), after a second on the middle digit of the indicator, the middle horizontal segment starts blinking at a frequency of 1 second.
        After pressing the ON button, the device starts up without any problems, reacts to everything and behaves absolutely adequately. After switching off with the button, the blinking of the segment is also present on the indicator.
        Uхх (mma) = 50 volts, Uхх (tig) = 10 volts. Didn't try to cook.
        Shoveled the whole scheme. Suspicious signals are: at the drain of the STD6NF10 transistor, at the output from the IR1150, the Gachette signal from the FAN3100.
        Already starting to suspect microcontrollers. How can I check the normal operation of the MK?
        Anyone who has any ideas - please share.
        
        Welding inverters Fubag often brought in for repair with accompanying comments - “turns on but does not cook" or "works but no current“.
        
        These models have a very peculiar design of the power unit.
        
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        In most cases, the racks coming from the secondary winding of the power transformer burn out. In this case, the device stops cooking, as they say “no current“.
        
        So that the current appears, it is necessary to restore the connection between the rack and the power unit board, in other words, solder it.
        
        It's easier to say, and a little harder to do.
        
        Firstly armed with this gadget: Glowing Soldering Iron.
        
        We unsolder the board from the power unit.
        
        Now we have gained access to all the torn off and burnt-out racks, we can proceed to the restoration.
        
        The Fubag inverter restored in this way can still serve its owner.
        
        Attention!
        To avoid complications when repairing a welding inverter with your own hands - be careful, all responsibility is on you.
        
        Repair of welding inverters from Fubag and other manufacturers.
        
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        Repair of the welding inverter GYSMI 131
        
        Repair of the welding inverter FUBAG IN160 [1]
        
        Repair of welding inverter GYSMI 145
        
        2. diggerweb (14.06.2015 17:37) It depends on how it burned out.
        This is the Fubag IN 190 power unit.
        
        The area under the pillar of the power unit burned out. The white layer under the foil is the intact heat-conducting coating, the dark area is burnt down to the radiator.
        
        The burnout area is smeared with transparent silicone and a piece of mica is glued on top. Silicone is a common sealant, it does not burn or melt from high temperatures when we solder the rack. I used the silicone that comes with the repair kit for restore TV remotes, Something like that.
        
        After all this has dried to the surviving foil, we solder a copper patch and a stand to it. The transistor had to be moved a little, since the space allowed.
        
        And this is Fubag IN 160, here the situation is hopeless - the heat-conducting layer burned out not only under the rack but also under the transistors, this is already in the trash.
        
        Banned
        
        Posts: 503
        The Fubag in160 is similar to the GYSMI 161 circuitry.
        
        I continue to repair IN160, the NCP1055 microcircuit was replaced from another batch, dead transistors Q11S02 = Q11S01 = BSR14, replacement from a donor, dead optocouplers U12X01, U41X01. The duty room has started up, the fan is spinning. The S17LITE05 processor does not issue a PWM signal, therefore the power section does not start. I took off the force, unsoldered the comb, I did not find any broken elements.
        Does anyone have a power section diagram?
        
        S17LITE05 was thrown from the donor, there are no changes, not the fact that it is whole.
        
        Banned
        
        Posts: 1960
        Welding equipment: Description, Specifications, Instructions, catalogs, schematic diagrams, Discussion, Reviews.
        
        Homeland of the brand: Germany
        Country of origin: China
        Official site: Fubag
        
        Intuitive controls and smart functionality
        Weighing only 5.1 kg, the device has excellent performance and confidently copes with tasks of varying degrees of complexity. The IN 203 single-phase DC welding inverter is perfect for various welding jobs in the workshop, garage, as well as in hard-to-reach places. Due to its excellent arc ignition and welding properties, the device allows you to confidently work with electrodes with a diameter of 5 mm with a coating from basic to rutile cellulose.
        Excellent welding. Easy start
        Easy to operate and operate, the inverter is capable of a lot. Equipped with high-tech functions Arc Force, Hot Start, Anti Stick, providing easy ignition and high arc stability.
        Aweigh. In hard-to-reach places
        Convenient shoulder strap with adjustment, compact size and light weight make it easy to change position during work, move with the device from object to object, as well as effortlessly and discomfort to work even in hard-to-reach places. Autonomous work
        In the absence or temporary shutdown of the central power supply, it confidently operates from a mobile power plant with a capacity of at least 7 kW.
        
        Supplied by the manufacturer:
        Inverter welding machine Fubag IN 203
        Copper cable with electrode holder, m 2.0 (red or black)
        copper grounding cable with a clamp, m 2.0
        Shoulder strap.
        Case optional
        Manual.
        
        220
        Power consumption, kW 7.0
        No-load voltage, V 72
        Welding current range, A 10 - 200
        Welding current at PV X% and t = 20 deg. C, A 120 (60%)
        Electrode diameter min, mm 1.6
        Electrode diameter max, mm 5.0
        Overall dimensions of the case, (LxWxH), mm 420x170x370
        Weight, kg 5.0
        
        If you have experience using this device, we will be grateful to you
        for an objective and detailed review that will help
        understand the advantages and disadvantages of the presented device.
        
        Hello everyone. The other day, a welding inverter was brought to the repair, perhaps my note about this repair will be useful to someone.
        
        This is not the first welding machine that had to be done, but if in one case the malfunction manifested itself like this: He switched on the inverter to the network ... and broads, knocked out the circuit breakers in the electrical panel. As the autopsy in the welder showed, the output transistors broke through, after the replacement everything worked.
        
        But in this case, everything was somewhat different, according to the owner, the device at times stopped cooking, although the power-on indicator was on. These guys themselves opened the case - they tried to determine the malfunction and noticed that the inverter reacted to the bending of the board, i.e. when it was bent, it could work. But when the welding inverter came to me, it did not turn on at all, even the on indicator did not light up.
        
        "Titan - BIS - 2300" - it was this model of the inverter that was repaired, the circuitry repeats the welding machine of the same power of "Resant" and, as I suppose, many other inverters. You can view and download the diagram here.
        
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        In this welding machine, a pulsed power supply is used to power low-voltage circuits, and it was just it that was faulty. The UPS is based on the UC 3842BN PWM controller. Analogues - domestic 1114EU7, Imported UC3842AN differs from BN only in lower current consumption, and КА3842BN (AN). See UPS diagram below. (Click on it to enlarge) The voltages that were already supplied by the working UPS are marked in red. Please note that you need to measure the 25V voltage not relative to the common minus, namely from the points V1 +, V1- and also V2 +, V2- they are not connected to the common bus.
        
        The UPS key is made on a transistor, field 4N90C. In my case, the transistor remained intact, but the microcircuit required replacement. There was also an open circuit resistor R 010 - 22 Om / 1Wt. After that, the power supply unit started working.
        
        However, it was too early to rejoice, having measured the voltage at the output of the welder, it turned out that it was not there, and in idle mode it should be about 85 volts. I tried to move the board, remember from the words of the owner it affected, but nothing.
        
        Further searches revealed the absence of one of the voltages of 25 volts at points V2-, V2 +. The reason is an open circuit in the winding transformer 1-2. Had to drink a trance, used a medical needle to release the conclusions.
        
        In the transformer, one of the ends of the winding was cut off from the terminal.
        
        We carefully restore the connection using a suitable wiring, the restored connection will not be superfluous to fix it with a drop of glue or sealant. I had polyurethane glue at my fingertips and used it, we revise other conclusions, if necessary, we solder.
        
        Before installing the transformer, you should prepare the board so that it fits into its place without effort. To do this, you need to clean the holes from the remnants of solder; this can also be done with a needle from a syringe of a suitable diameter.
        
        After installing the transformer, the welding inverter started working.
        
        How to check the microcircuit without unsoldering it from the board and what else to pay attention to.
        
        You can partially check the microcircuit if you have a voltmeter and an adjustable stabilized constant voltage source. A signal generator and oscilloscope are required for a complete test.
        
        Let's talk about what is easier. Be sure to turn off the power to the inverter before checking. Further - from the external regulated power supply to pin 7 of the microcircuit, we apply a voltage of 16 - 17 volts, this is the starting voltage of the MS. In this case, at pin 8 there should be 5 V. this is the reference voltage from the internal stabilizer of the microcircuit.
        
        It should remain stable when the voltage at pin 7 changes. If not, the MS is faulty.
        
        When changing the voltage on the microcircuit, keep in mind that below 10 V, the microcircuit turns off, and turns on at 15-17 volts. You should not increase the supply voltage of the MS above 34 V There is a protective zener diode inside the microcircuit and if the voltage is too high, it will simply break through.
        
        Below is a block diagram of the UC3842.
        
        Addendum to this article: After a while, another apparatus was brought. Out of order due to falling on its side.This happened because during the operation the screws holding the case loosened, and some were simply lost, so when the board fell, it played and touched the case with the mounting side.As a result of the short circuit, all 4 output transistors K 30N60HS failed. Analogs G30N60A4D, G40N60UFD. After the replacement, everything worked.
        
        That's all! If you found this article useful, leave your comments, share with your friends by clicking on the social media buttons.
        
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