Electric fusion welding machine troubleshooting and solutions- Hangzhou Fuyi Tools Co., Ltd

Electric fusion welding machines are essential equipment for welding plastic pipes and are widely used in industries such as water supply and drainage, gas, and chemicals. Due to the complex working environment, various equipment failures are unavoidable during use, affecting welding quality and project progress.

1. Common Faults and Symptoms
Power Failure
Symptoms: After powering on, the device is completely unresponsive, with no indicator lights, no display on the control panel, and no operation.
Possible Causes and Detailed Analysis:
Power Cord Disconnected or Poor Contact: The power cord is broken or the plug is loose, preventing proper current flow to the device.
Blown Fuse: The internal fuse of the device protects the circuit. When the current is abnormal, the fuse will blow, shutting off the circuit and preventing further damage.
Power Switch Fault: The internal contacts of the switch are aged or damaged, preventing power from flowing.
Power Outlet No Power: The external power supply circuit is faulty or the power outlet is damaged.

Abnormal Welding Temperature
Symptoms: The welding temperature displayed by the device deviates significantly from the set value, either too high or too low, or even fails to heat.
Possible Causes and Detailed Analysis:
Damaged or Failed Temperature Sensor: The sensor cannot detect the actual temperature, causing the control system to incorrectly adjust the heating power.
Loose or broken temperature sensor cable: Unstable signal transmission affects the controller's judgment.
Control Circuit Fault: The mainboard or temperature control module is damaged, preventing proper regulation of the heating element. Heating element aging: Abnormal resistance in the heating wire leads to uneven or insufficient heating.

Inaccurate welding time

Symptoms: The welding timer stops abnormally, the welding time is significantly longer or shorter than the set time, or the welding process is unexpectedly interrupted.

Possible causes and detailed analysis:

Time relay failure: The time relay controls the welding duration. Failure can lead to timing control errors.

Control chip or mainboard program error: An internal software program failure or data error occurs.

External interference causes the controller to restart or malfunction: Electromagnetic interference or unstable power supply can cause control system malfunctions.

Poor heating uniformity

Symptoms: Overheating in some areas of the pipe during welding causes deformation, while other areas are underheated, resulting in a weak weld.

Possible causes and detailed analysis:

Broken or partially damaged heating wire: A short circuit or abnormal resistance in the heating wire leads to uneven heating in certain areas.

Contaminated or oxidized contact electrodes: Dirt or rust on the electrode surface affects current conduction, resulting in unstable heating.

Loose contact between the electrode and the pipe: Improper installation results in insufficient contact surface, causing localized temperature unevenness.

The display is not displaying or is displaying abnormally.
Symptom: After turning on the device, the display does not light up or displays garbled or flickering characters.
Possible Causes and Detailed Analysis:
Loose or damaged display cable: Poor cable contact causes signal transmission failure.
Fault in the display module: Damage to internal display components.
Abnormal power supply to the main control board: The main board is unable to properly power the display.

2. Troubleshooting Steps
Check the power supply
Use a tester or multimeter to verify that the power outlet is powered.
Check the device's power cord for breaks, wear, or loose connectors.
Open the device's casing, locate the fuse, and check if it is blown. If damaged, replace it with a fuse of the same specification.
Use a multimeter to check the power switch to confirm that it is functioning properly.

Check the sensor and control circuitry: Disconnect the temperature sensor cable and measure the sensor resistance with a multimeter. Refer to the device manual to confirm that it is within the normal range.
Check the sensor circuitry for breaks or shorts.
Inspect the main control board for burnt, discolored, or loose components. If necessary, remove the temperature control module and conduct further testing using an oscilloscope or specialized test equipment.

Check the heating element.
Use an ohmmeter to measure the resistance across the heating wire. Normal resistance varies slightly depending on the device model. If the heating element is broken or has abnormal resistance, replace the heating element.
Remove the heating electrode and clean the contact surface between the electrode and the pipe, ensuring it is free of oil, dirt, or rust.
Check that the heating wires are evenly arranged to prevent local overheating.

Software Reset and Upgrade.
Refer to the device's operating manual for software reset steps and restore the device to factory settings.
Check the manufacturer's official website or contact customer service for the latest firmware version and upgrade the device software using the designated tool.
Back up important parameters before upgrading and perform a test calibration afterward.

Check the display and connection cables.
Open the device and check that the display cable is securely plugged in and is not bent or broken.
Use a multimeter to check for broken cables.
Replace the display module to troubleshoot the display.
Check the main control board's power supply circuits and components for integrity.

3. Solutions to common problems

Fault Type	Detailed Solution
Power Failure	Replace damaged power cables, check and replace fuses, repair or replace power switch, ensure power outlet supply is normal.
Temperature Abnormality	Replace faulty temperature sensors, repair or replace control circuit board, check and replace aging heating elements.
Inaccurate Welding Time	Replace faulty timer relay, upgrade device software, eliminate external electromagnetic interference, check main control board chips.
Uneven Heating	Replace broken or faulty heating elements, clean or replace contact electrodes, ensure proper installation and good contact.
Display Issues	Reconnect display cable, replace damaged display module, check power supply and signal lines on the main control board.

4 Preventive Measures and Maintenance Recommendations
Regularly inspect power lines and components: Check the power cord monthly for signs of wear and ensure the plug is secure to prevent malfunctions caused by poor contact.
Clean the interior and exterior of the device: Use a clean, soft cloth to remove dust to prevent accumulation that could affect heat dissipation and circuitry.
Perform a pre-use self-test: Before turning on the device, check that the temperature sensor and heater are functioning properly and that the display is displaying normally.
Maintain a well-ventilated working environment: Avoid overheating and excessive humidity to extend component life.
Avoid prolonged overload operation: Limit continuous operation to a minimum of 24 hours, requiring adequate rest intervals.
Regularly calibrate and update software: Contact the manufacturer for device calibration to ensure accurate parameters. Install the latest firmware provided by the manufacturer to fix bugs.