160TM dead after 6 years - repairable??

[perry3188]

Hi all

A week or so ago I fitted a new euro torch (previously converted when new) to my 160TM as the trigger was not working sometimes. It seemed to fix the problem but something still seemed off with the welder.

Yesterday I was welding above my head (near the ceiling) some 1.6mm wall tube to 3mm wall tube on full power and it was like it was on the lowest power setting. I was getting no penetration in the thicker tube. So I made up a test on the bench of the same exact metals and it welded perfectly, practically blowing holes in the thinner stuff. I went back to the job, double checked earth and settings etc - still no good!

So I borrowed another euro torch from the garage next door to rule out my new one, and as I was feeding the wire through the liner by pressing the trigger, the mig started spewing smoke out from inside the business side of the machine and it stank of fried electrics! Also the supply cable from the 13A plug was really hot and floppy. I let it cool down and then fired it up again, just pressed the trigger for a few seconds to feed some more wire and the cable became immediately hot again.

I haven't opened it up yet as I though I'd ask on here what if anything I should be looking for and testing. I wouldn't mind using this as an excuse to buy the R-Tech mig180 but if it's still economical to repair I'd like to keep this going a while longer.

Any help appreciated!

 

[gaz1]

it reads as if your transformer has melted itself

 

[perry3188]

Do you know how I can test the components? Like what should the output of the transformer be? If it is the transformer are they replaceable? Economically, I mean.

 

[steviec_lj]

Economically, you’d probably spend the same on a new welder with a warranty.

 

[perry3188]

I've been reading the online manual and it says this:

SECONDARY or OUTPUT POWER DATA
Sec. Volts 18 - 28 V
Max. Sec. Amps 150 Amps

Would the voltages be measured at the rectifier or the transformer?

 

[gaz1]

if you want to test it dont test it with power on

you need to test see if theres a direct connection from transformer to the power leads first then go from there something is earthing the power when switch on its direct hence the reason why your power cables are melting heating up

 

[voipio]

Take a look inside to see where the magic smoke came from.

 

[Tom O]

My Millermatic 130 did that it was a capacitor gone and I replaced all six for $300 Canadian.

 

[merryman]

Just had a thought on this one, someone else had a similar problem and it was the earth lead for welding come off inside the case and fallen onto the case. Only way for welding power to get to workpiece was via the mains side earth wire. Some on here will say impossible, but the fact that you were having problems with the bench being OK and welding overhead not, could be a clue.

 

[perry3188]

I'll tear her apart in the morning and see what's what.

 

[perry3188]

Problem found and problem solved!

As soon as I opened it up it was obvious what had fried, it was the earth cable from the mains. So I started checking things and found the euro torch connector body was not fully insulated. How it's lasted 6 years without fail I'll never know

So I fitted the euro connector properly, a new power cable and for good measure did a proper job of joining the upgraded earth clamp cable to the choke. A good blow out with the compressor and shes welding as good as new again

I might start a new thread for this one, but has anyone done a capacitor modification?