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Fronius 1500 TransPocket Welder - External Control Failure After Mod Attempt

Mazii666 9438 1
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  • #1 12896801
    Mazii666
    Level 11  
    Hello, I have a problem with the Fronius 1500 transpocket welding machine. Maybe from the beginning, a potentiometer was supposed to be added to the welding machine to control the welding current on the cable, i.e. External control with switch for selecting the control potentiometer. This was to be done by a switch of the two-state ON-ON type, picture. After putting everything together, I waited for a new potentiometer identical to the one used in the welding machine, i.e. 25k. Unfortunately, I temporarily soldered a 10k potentiometer onto the external cable to check it and, unfortunately, I left it there. My father came and wanted to see how it worked and connected it. As long as he was welding on the welding machine`s control, everything was apparently OK. After switching the control to external, all the diodes lit up and since then the control has not worked. The welder produces an arc normally, but the current cannot be increased or decreased. The potentiometer is OK. (checked) the diode in the welding machine on the board (marked in Figure 2,3,4) reacts to turning the potentiometer and lights up brighter and darker as it is turned. 5v is supplied to the potentiometer. The voltages at the control points match, figure 5. At idle speed it is approximately 75V. What can I check and what could be damaged? Thanks for any suggestions. Edit: added 2 pictures with damaged resistors and a question on how to check the systems next to them. The chips are SG3644M
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  • #2 21049432
    MaazKhalid
    Level 1  
    Ensure it's functioning correctly, as the 5V supply to the potentiometer is crucial.
    Verify that none of the diodes (D1-D4) are damaged or short-circuited.
    Double-check the wiring and connections to the potentiometer, ensuring they're secure and correct. Re-check the voltage levels at the control points to ensure they're within the expected ranges.
    Ensure the welding machine settings are correct and not causing the issue.
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