Inverter Technology 175 210 188GE

Cod. 988672

CONTENTS PAGE

OPERATION AND WIRING DIAGRAMS................ 2 Block diagram 2 Analysis of the block diagram 3 Illustrations 5 Wiring diagrams 6

REPAIR GUIDE.......................................................11 Equipment required 11 General repair instructions 12 Troubleshooting and remedies 12 Testing the machine 15 Illustrations 18

SPARE PARTS LIST...............................................19

REPAIR SHEET......................................................23

TROUBLESHOOTING

AND REPAIR MANUAL

TROUBLESHOOTING

AND REPAIR MANUAL

TROUBLESHOOTING

AND REPAIR MANUAL

TROUBLESHOOTING

AND REPAIR MANUAL

“reparation no problem !”

TECNICA 140.1 - 142inver ter

TECHNOLOGY 175-210-188CE/GE

- 2 -

BLOCK DIAGRAM

OPERATION AND WIRING DIAGRAMSOPERATION AND WIRING DIAGRAMSOPERATION AND WIRING DIAGRAMSOPERATION AND WIRING DIAGRAMS

24

SH

UN

T A

MP

LIF

IER

+ |

28PO

WER

SU

PP

LY

LED

6CU

RR

ENT

TRA

NS

FOR

MER

1EM

C F

ILTER

7PO

WER

T

RA

NS

FOR

ME

R

10SECO

ND

ARY

EMC

FILT

ER

CO

NT

RO

L

8SEC

ON

DA

RY

D

IOD

ES

5CH

OP

PER

4FILT

ER

3PR

E-C

HA

RG

E

2REC

TIF

IER

BR

IDG

E

9INDU

CTAN

CE A

ND

SHUN

T +

-

1329FA

N

27UN

DER

VO

LTA

GE

SA

FEG

UA

RD

V

t

23MA

XIM

UM

C

UR

RE

NT

A

DJU

STM

ENT

21

CU

RR

EN

T

PO

TEN

TIO

MET

ER

14

20ALA

RM

LED

22WE

LD

ING

P

RO

CE

DU

RE

FU

NC

TIO

N

SE

LE

CT

OR

MM

A

TIG

-LIF

T2

6

SE

CO

ND

AR

Y D

IOD

E

TH

ER

MO

STA

T

25

PO

WER

TR

AN

SFO

RM

ER

THER

MO

STA

T

17AD

DE

RA

LA

RM

BL

OC

K

19

11AU

XIL

IAR

Y

SU

PP

LY

12TER

TIA

RY

SU

PP

LY

16DU

TY

CY

CL

E

MA

KE

R

18PRIM

ARY

CUR

REN

T R

EAD

ER

AND

LIM

ITER

TRA

NS

FOR

MER

P

ILO

T

15

OU

TPU

TIN

PU

T

SE

PA

RA

TOR

TR

AN

SFO

RM

ER

DR

IVER

IG

BT


- 3 -

ANALYSIS OF THE BLOCK DIAGRAM

NOTE: Unless indicated otherwise, it should be assumed that the components are assembled on the power board.

Block 1EMC FilterConsisting of: C24, C25, C26, L2.Prevents noise from the machine from being transmitted along the main power line and vice versa.

Block 2Rectifier bridgeConsisting of: D31, D32.Converts the mains alternating voltage into continuous pulsed voltage.

Block 3Pre-chargeConsisting of: K1, K2, R40.Prevents the formation of high transitory currents that could damage the main power switch, the rectifier bridge and the electrolytic capacitors.When the power source is switched on the relay K1 and K2 are de-energised, capacitors C27, C29, C30, C31 are then charged by R40 When the capacitors are charged the relay is energised.

Block 4FilterConsisting of: C27, C29, C30, C31.Converts the pulsed voltage from the rectifier bridge into continuous voltage.

Block 5ChopperConsisting of: Q6, Q7, Q8, Q9.Converts the continuous voltage from the filter into a high frequency square wave capable of piloting the power transformer.Regulates the power according to the required welding current/voltage.

Block 6Current transformerConsisting of: T1.The C.T. is used to measure the current circulating in the power transformer primary and transmit the information to block 17 (primary current reader and limiter).

Block 7Power transformerConsisting of: T4.Adjusts the voltage and current to values required for the welding procedure. Also forms galvanic separation of the primary from the secondary (welding circuit from the power supply line).

Block 8Secondary diodesConsisting of: D46, D47, D48, D49, D51.D46, D47, D48 converts the current circulating in the transformer to a single direction, preventing saturation of the nucleus.D49, D51 recirculate the inductance output current (block 9) when the IGBT's are not conducting, bypassing the power transformer (block 7).

Block 9Inductance and shuntConsisting of: L1, R38. The inductance levels the secondary board diodes' output current making it practically continuous/direct. The shunt reads the current circulating in the inductance and sends it to block 24 (shunt amplifier), which will process the data.

Block 10Secondary EMC FilterConsisting of: C21, C22.Prevents noise from the power source from being transmitted through the welding cables and vice versa.

Block 11Auxiliary supply Constisting of: T2, D1, Q2, U5Takes and stabilizes the voltage coming from block 2 (rectifier bridge) and makes it suitable to supply correctly: block x (supply led) block x (transformer separator) and block 3 (pre-charge).

Block 12Tertiary supply Constisting of: D11, D57, Q0,D8Takes and stabilizes the voltage coming from tertiary wiring block 7 (power transformer) and makes it suitable to supply correctly block x (fans) and block 3 (pre-charge).

Block 13Separator transformerConsisting of: T3.Supplies two signals, which are separated galvanically from one another, that will be sent to power block 14 (driver).

Block 14DriverConsisting of: Q5, D19, D20, Q10, D25, D26.Takes the signal from block 13 (flyback power supply) and, controlled by block 15 (duty cycle maker), makes the signal suitable for piloting block 5 (chopper).

Block 15Transformer PilotConsisting of: Q4, D14, D15, D16.Amplifies the signal arriving from block 16 (duty cycle maker), needed to pilot block 13 (separator transformer).

Block 16Duty cycle makerConsisting of: U2 (control board).Processes the information from block 17 (adder) and block 18 (primary current reader and limiter) and produces a square wave with variable duty cycle limiting the primary current to a maximum pre-set value under all circumstances.

Block 17AdderConsisting of: U1C (control board).Gathers all the information from block 18 (primary current reader and limiter), from block 19 (alarms) and from block 21 (current potentiometer), and produces a signal with a suitable voltage for processing by block 16 (duty cycle maker).


- 4 -

Block 27Undervoltage safeguardConsisting of: R7, R9 and part of control board.If the main supply voltage falls below the minimum allowed value this safeguard triggers (a tolerance of approx. ±15% of the power supply voltage is allowed: outside this range the safeguard triggers).

Block 28Power supply LEDConsisting of: D43.Indicates when the power source is correctly powered and ready for use.

Block 29FanConsisting of: V1, V2.Powered directly by block 12 (Tertiary supply) and cools the power components.

Block 18Primary current reader and limiterConsisting of: R79, R80, R81, R82, R83, R84 (control board).Reads the signal from block 6 (current transformer) and scales it down so it can be processed and compared in block 16.

Block 19Alarm BlockConsisting of: U1A (control board).When an alarm is detected the power source output current is drastically reduced by making direct adjustments to block 16 (duty cycle maker) and directly changing the reference signal obtained from block 21 (current potentiometer).

Block 20Alarm LED Consisting of: D39.It is switched on by block 19 (alarms) in the event of:1) Triggering of thermostatic capsule/thermostat on power

transformer.2) Triggering of thermostatic capsule on secondary

diodes.3) Triggering due to undervoltage.4) Short circuit at output (electrode holder clamp and earth

cable connected to one another or electrode stuck to piece being welded).

Block 21Current potentiometerConsisting of: R49.This is used to set the reference voltage needed to adjust the output current: when the potentiometer knob is turned the cursor voltage varies, thus varying the current from the minimum to the maximum value.

Block 22Welding procedure function selectorConsisting of: SW1The switch is used to select the type of welding process: MMA, TIG-LIFT.

Block 23Maximum current adjustmentConsisting of: R48, R55.Used to adjust the maximum cutting current to be supplied by the power source.

Block 24Shunt AmplifierConsisting of: U3A (control board)Amplifies the signal from block 9 (inductance shunt) and makes it appropriate for block 17 (Adder).

Block 25Power transformer thermostatConsisting of: ST2.When the temperature of the power transformer is too high, the thermostat transmit the information to block 19 (Alarm Block). It is reset automatically after the alarm condition has ceased.

19 (Alarm Block).

Block 26Secondary diode thermostatConsisting of: ST1When the temperature of the secondary diode dissipator reaches a given temperature the thermostat cuts in, sending an alarm signal to block It is reset automatically when this alarm condition is no longer present.


- 5 -

ILLUSTRATIONS

Power board

(5)CHOPPER

(22)WELDING

PROCEDURE FUNCTION SELECTOR

(11)AUXILIARY

POWER SUPPLY

(15)TRANSFORMER

PILOT

(13)SEPARATOR

TRANSFORMER

(1)PRIMARY EMC

FILTRE

(4)FILTER

(3)RECTIFIER

BRIDGE

(2)PRE-CHARGE

(8)SECONDARY

DIODES

CONTROLBOARD

(21)CURRENT

POTENTIOMETER

(28)POWER SUPPLY

LED

(20)ALARM

LED

(10)SECONDARYFILTER EMC

(9)INDUCTANCE AND SHUNT

(6)CURRENT

TRANSFORMER

(7)POWER

TRANSFORMER


Wiring diagramgeneral TECHNOLOGY 175 - 210 -188 CE/GE -

- 6 -

WIRING DIAGRAMS

+5V

+17V

8

GN

DD

R+

SH

-

TA+

TA-

SH

+VO

LT

-VO

LT+

POT_

IN

GN

DLE

DSWF

AU

LT

TAR

-VC

HEC

K

TAR

+

OU

T+

OU

T-

PO

WE

R P

CB

CO

NTR

OL

PC

B

ON

LY

FO

RG

E V

ER

SIO

N

J22

J22

V1

-V

1-

SH

-S

H-

541

2

S1

ON

/OF

F541

2

S1

ON

/OF

F

V1+

V1+

L1

Ind

utta

nce

L1

Ind

utta

nce

J21

J21

V

2

F

a

n V

2

F

a

n

PE

N (L2

)

L1PE

N (L2

)

L1

CN

11

CN

11

1 2 3 4 5 6 7 8 9 10

11

12

13

14

15

16

17

18

19

20

21

22

J3

1 2 3 4 5 6 7 8 9 10

11

12

13

14

15

16

17

18

19

20

21

22

J3

CN

4C

N4

1 2 3 4 5 6 7 8 910

11

12

13

14

15

16

17

18

19

20

21

22J7 1 2 3 4 5 6 7 8 9

10

11

12

13

14

15

16

17

18

19

20

21

22J7

CN

9C

N9

R38

Shun

tR

38

Shun

t

V

1

F

a

n V

1

F

a

n

V

2

+ V

2

+

V

2 -

V

2

-


Wiring diagram power board - primary

- 7 -

S

H

+

V

C

H

E

C

K

V

O

L

T

-

T

A

- P

O

T

I

N

D

R

+

T

A

+

S

H -

V

O

L

T

+

T

A

R

+

T

A

R

-

C

A

D

M

C

A

D

A

C

A

D

1

C

A

D

2

F

A

U

L

T

S

W

L

E

D

+

5

V B

+

5

V

+

1

7

V

8

B

+17V

8

B

B

+

5

V

+17V

8

C

O

R

R

R55

TEC

HN

OLO

GY

175

IGB

T Q

6, Q

7,

Q8

, Q9

D31

, D32

MO

DE

L

TEC

HN

OLO

GY

210

C29

, C30

, C31

K1

, K2

SG

W30N

60

SG

W30N

60

D31

= G

BPC

3508

/10

D

32

= G

BPC

3508

/10

JP1

OF

F

OF

F

I

M

A

X

TIG

MM

A

680u

400V

All

470u

400V

All

D31

= G

BPC

3508

/10

D

32

= G

BPC

3508

/10

K1

= 1

5V

dc

45m

A/2

50V

16A

K

2 =

15V

dc

45m

A/2

50V

16A

K1

= 1

5V

dc

45m

A/2

50V

16A

K

2 =

15V

dc

45m

A/2

50V

16A

27K

0W

25

5%

10K

0W

25

5%

JP2

ON

ON

470u

450V

All

ON

OF

FD

31

= 3

6MB

100A

D

32

= N

.M.

TEC

HN

OLO

GY

188G

E/C

ESG

W30N

60

33K

0W

25

5%

K1

= 1

5V

dc

45m

A/2

50V

16A

K

2 =

15V

dc

45m

A/2

50V

16A

C28

470u

450V

All

N.M

.

N.M

.

1 2 3 4 5 6 7 8 9 1

0

1

1 1

2

J

8

F o r i _ 1 2 p a s s o 2 . 5

1 2 3 4 5 6 7 8 9 1

0

1

1 1

2

J

8

F o r i _ 1 2 p a s s o 2 . 5

TP

6TP

6

R

5

6

N .

M

.

R

5

6 N

.

M .

TP

24

TP

24

D32

V.T

.D

32

V.T

.C

26

4n7

250V

KP

C26

4n7

250V

KP

JP2

V.T

.JP

2V

.T.

Q8

V.T

.Q

8V

.T.

R

4

8

4

7

K

2

0

T

0

W

5

1

0

%

R

4

8

4

7

K

2

0

T

0

W

5

1

0

%

T

P

2

1

T

P

2

1

R39

1M 0W

5 5%

R

39

1M 0W

5 5%

R43

1R

0W

25

5%

R43

1R

0W

25

5%

1 2 3 4 5 6 7 8 9 1

0

1

1 1

2

1

3 1

4

1

5 1

6

1

7 1

8

1

9 2

0

2

1 2

2

J

7

F o r i 2 2 p a s s o 2 . 5

1 2 3 4 5 6 7 8 9 1

0

1

1 1

2

1

3 1

4

1

5 1

6

1

7 1

8

1

9 2

0

2

1 2

2

J

7

F o r i 2 2 p a s s o 2 . 5

CN

4

Fa

sto

n-M

6,3

x0,8

CN

4

Fa

sto

n-M

6,3

x0,8

CN

11

Fa

sto

n-M

6,3

x0,8

CN

11

Fa

sto

n-M

6,3

x0,8

C44

100u

25V

All

C44

100u

25V

All

TP

39

TP

39

TP

5TP

5

L2295uH

L2295uH

C34

10n

630V

KP

C34

10n

630V

KP

R14

3K

3 5W

10%

R14

3K

3 5W

10%

TP

9TP

9

C27

220n

630V

MK

PC

27

220n

630V

MK

P

TP

1TP

1

R

4

9

1

0

K

L I

N

0

W

2

1

0

% R

4

9

1

0

K

L I

N

0

W

2

1

0

%

TP

37

TP

37

T

P

8

T

P

8

D35

RU

RP

860

D35

RU

RP

860

D33

RU

RP

860

D33

RU

RP

860

R

1

2

N .

M

.

R

1

2 N

.

M .

R

1

3

N .

M

.

R

1

3 N

.

M .

C29

V.T

.C

29

V.T

.

D41

1N4148

D41

1N4148

C24

1u

275V

MK

PC

24

1u

275V

MK

P

T

P

1

6

T

P

1

6

Q9

V.T

.Q

9V

.T.

R42

1R

0W

25

5%

R42

1R

0W

25

5%

D34

N.M

.D

34

N.M

.

T

P

1

7

T

P

1

7

TP

2TP

2

R46

1R

0W

25

5%

R46

1R

0W

25

5%

D37

MU

R1560

D37

MU

R1560

SW1

1B

11

SW1

1B

11

D39

Gia

llo 5m

mD

39

Gia

llo 5m

m

T

P

2

0

T

P

2

0

R

5

5

V .

T

.

R

5

5 V

.

T .

K2

V.T

.K

2V

.T.

D

4

0

1

N

4

1

4

8

D

4

0

1

N

4

1

4

8

H2

Dis

sipa

tore

H2

Dis

sipa

tore

D38

MU

R1560

D38

MU

R1560

R

5

7

N .

M

.

R

5

7 N

.

M .

Q6

V.T

.Q

6V

.T.

TP

3TP

3

CN

8

N.M

.

CN

8

N.M

.

H1

Dis

sipa

tore

H1

Dis

sipa

tore

T

P

1

9

T

P

1

9

R50

2

K

2

0

W

25

5%

R50

2

K

2

0

W

25

5%

C

3

5

1

u

6

3

V

M

K

T

C

3

5

1

u

6

3

V

M

K

T

K1

V.T

.K

1V

.T.

C25

4n7

250V

KP

C25

4n7

250V

KP

T

P

2

3

T

P

2

3

F15246C

Pow

er b

oa

rd T

echno

log

y_C

TR

AFO

_PN

TR

AFO

_P

P

S H +

S H -

RE

LP

V O L T -

T A -

SP

-

V O L T +

T A +

SP+

T E R M I C O

R45

20R

13W

5%

R45

20R

13W

5%

C28

N.M

.C

28

N.M

.

T

P

2

2

T

P

2

2

C31

V.T

.C

31

V.T

.

F15246B

Pow

er b

oa

rd T

echno

logy_

B

DR

+

E M E T _ H

G A T E _ H

G A T E _ L

E M E T _ L

VC

HEC

K

RE

LE_K

1_A

RE

LE_K

1_B

RE

LE_K

2_A

AC

+

RE

LE_K

2_B

RE

LP

AC

-S

P+

SP

-

TP

40

TP

40

D31

V.T

.D

31

V.T

.

T

P

1

8

T

P

1

8

TP

7TP

7

D36

N.M

.D

36

N.M

.

R40

47R

8W

5%

R40

47R

8W

5%

Q7

V.T

.Q

7V

.T.

R44

20R

13W

5%

R44

20R

13W

5%

C33

10n

630V

KP

C33

10n

630V

KP

CN

9

Fa

sto

n-M

6,3

x0,8

CN

9

Fa

sto

n-M

6,3

x0,8

TP

4TP

4

H3

Dis

sipa

tore

H3

Dis

sipa

tore

TP

10

TP

10

TP

38

TP

38

R47

1R

0W

25

5%

R47

1R

0W

25

5%

T

P

1

1

T

P

1

1

JP1

V.T

.JP

1V

.T.

C30

V.T

.C

30

V.T

.


- 8 -

Wiring diagram power board - power / driver

VC

HEC

K

AC

+

AC

-

SP+ SP

-

GA

TE

_L

GA

TE

_H

EME

T_H

EME

T_

L

D

R

+

RE

LE_K

2_A

RE

LE_K

1_A

RE

LE_K

1_B

RE

LE_K

2_B

RE

LP

+17V

8

B

+17V

8

B

B

+5V

20V

B

B

+

1

7

V

8

H4

H4

D22

18V

0W

4 5%

D22

18V

0W

4 5%

1

2 3

Q

1

0

B

C

3

2

7

Q

1

0 B

C

3

2

7

C14

N.M

.C

14

N.M

.

R

2

9

4

7

0

R

0

W

2

5

5

%

R

2

9

4

7

0

R

0

W

2

5

5

%

D

5

2

N .

M

.

D

5

2 N

.

M .

D24

18V

0W

4 5%

D24

18V

0W

4 5%

D8

15V

0W

4 2%

D8

15V

0W

4 2%

D21

18V

0W

4 5%

D21

18V

0W

4 5%

18

654 3

T

3

T

I

1

1

7

3

0

3

T

3

T I

1

1

7

3

0

3

T

P

3

4

T

P

3

4

2no

so

lde

r2

no

so

lde

r

C11

100u

63V

All

C11

100u

63V

All

12 3

Q

5

B

C

3

2

7

Q

5 B

C

3

2

7

D10

BY

V27

-200

D10

BY

V27

-200

R8

3K

3 0W

5 5%

R8

3K

3 0W

5 5%

D23

18V

0W

4 5%

D23

18V

0W

4 5%

R59

10K

0W

25

5%

R59

10K

0W

25

5%

D

2

0

B

Y

V

2

7 -

2

0

0

D

2

0 B

Y

V

2

7

-

2

0

0

TP

32

TP

32

TP

27

TP

27

D54

1N4148

D54

1N4148

Q0

TIP

122

Q0

TIP

122

C

1

5

1

u

6

3

V

M

K

T

C

1

5

1

u

6

3

V

M

K

T

C9

1u

63V

MK

TC

91u

63V

MK

T

-V1

-V1

D55

10V

0W

4 5%

D55

10V

0W

4 5%

V1

12V

dc

V1

12V

dc

R

3

1

1

0

R

0

w25

5%

R

3

1

1

0

R

0

w25

5%

D1

W02G

D1

W02G

C43

47u

25V

All

C43

47u

25V

All

D6

1N4148

D6

1N4148

R30

1

K

0

W

25

5%R30

1

K

0

W

25

5%

C1

470u

50V

All

C1

470u

50V

All

Q2

TIP

50

Q2

TIP

50

D

5

3

N .

M

.

D

5

3 N

.

M .

C36

1n

100V

X7R

C36

1n

100V

X7R

C38

1u

63V

MK

TC

38

1u

63V

MK

T

C

1

9

N .

M

.

C

1

9 N

.

M .

TP

26

TP

26

C42

33u

25V

All

C42

33u

25V

All

D

1

6

B

Y

V

2

7

-

2

0

0

D

1

6

B

Y

V

2

7 -

2

0

0

C37

1n

100V

X7R

C37

1n

100V

X7R

D56

N.M

.D

56

N.M

.

TP

28

TP

28

R1

470R

2W

5%

R1

470R

2W

5%

TP

31

TP

31

+V

1+

V1

D11

BY

V27

-200

D11

BY

V27

-200

C2

10u

25V

All

C2

10u

25V

All

D4

1N4148

D4

1N4148

TP

25

TP

25

2

31 Q1

MP

SA

13

Q1

MP

SA

13

C40

33u

25V

All

C40

33u

25V

All

IN1

OU

T3

GND2

U5

LM78

L05

U5

LM78

L05

TP

29

TP

29

D57

BY

V27

-200

D57

BY

V27

-200

D3

18V

1W

5%

D3

18V

1W

5%

+V

2+

V2

D43

Ve

rde

5mm

D43

Ve

rde

5mm

T2

230

/18

4V

AT2

230

/18

4V

A

D

1

5

1

0

V

0

W

4

5

% D

1

5

1

0

V

0

W

4

5

%

R

3

4

4

7

0

R

0

W

2

5

5

%

R

3

4

4

7

0

R

0

W

2

5

5

%

C

1

8

N .

M

.

C

1

8 N

.

M .

R51

3K

3 0W

5 5%

R51

3K

3 0W

5 5%

C8

100N

63V

MK

TC

8100N

63V

MK

T

R

2

8

1

2

0

R

0

W

2

5

5

%

R

2

8

1

2

0

R

0

W

2

5

5

%

D

1

8

B

Y

V

2

7 -

2

0

0

D

1

8 B

Y

V

2

7

-

2

0

0

R

3

3

1

0

R

0

W

25

5%

R

3

3

1

0

R

0

W

25

5%

C

1

7

1

u

6

3

V

M

K

T

C

1

7

1

u

6

3

V

M

K

T

D

1

7

B

Y

V

2

7 -

2

0

0

D

1

7 B

Y

V

2

7

-

2

0

0

V2

12V

dc

V2

12V

dc

TP

30

TP

30

C6

10u

25V

All

C6

10u

25V

All

R58

22R

0W

5 5%

R58

22R

0W

5 5% R32

1

K

0W25

5%

R32

1

K

0W25

5%

C

1

6

1

u

6

3

V

M

K

T

C

1

6

1

u

6

3

V

M

K

T

R

2

6

1

K

0

W

2

5

5

%

R

2

6

1

K

0

W

2

5

5

%

C

4

1

3

3

u

2

5

V

A

l l

C

4

1

3

3

u

2

5

V

A

l l

1 no

so

lde

r1 no

so

lde

r

TP

33

TP

33

D

2

6

B

Y

V

2

7 -

2

0

0

D

2

6 B

Y

V

2

7

-

2

0

0

D

1

4

1

0

V

0

W

4

5

% D

1

4

1

0

V

0

W

4

5

%

Q

4 I

R

F

D

1

1

0

Q

4 I

R

F

D

1

1

0

R9

12K

0W

25

5%

R9

12K

0W

25

5%

-V2

-V2

R

2

5

2

2

0

R

0

W

2

5

5

%

R

2

5

2

2

0

R

0

W

2

5

5

%

C3

470u

25V

All

C3

470u

25V

All

C10

1u

63V

MK

TC

10

1u

63V

MK

T

R

2

7

1

2

0

R

0

W

2

5

5

%

R

2

7

1

2

0

R

0

W

2

5

5

%

D

1

9

B

Y

V

2

7 -

2

0

0

D

1

9 B

Y

V

2

7

-

2

0

0

D2

1N4004

D2

1N4004

D7

10V

0W

4 5%

D7

10V

0W

4 5%

C39

1u

63V

MK

TC

39

1u

63V

MK

T

D

2

5

B

Y

V

2

7 -

2

0

0

D

2

5 B

Y

V

2

7

-

2

0

0


Wiring diagram power board - secondary

- 9 -

VO

LT

-

SH

-

SH

+

VO

LT+

RE

LP

T

R

A

F

O

_

P

P

T

R

A

F

O

_

P

N

S

P

+

T

A

+ S

P

-

T

A

-

TE

RM

ICO

B

BB

OU

T-

OU

T+

A

B

D46

, D48

D47

= N

.M.

D47

= N

.M.

D47

D46

= S

TTH

6003C

W

D48

= S

TTH

6003C

W

D46

= S

TTH

6003C

W

D48

= S

TTH

6003C

W

TEC

HN

OLO

GY

175

MO

DE

L

TEC

HN

OLO

GY

210

D47

= S

TTH

6003C

WD

46

= N

.M.

D48

= N

.M.

TEC

NO

LOG

Y 1

88C

E/G

E

D30

N.M

.D

30

N.M

.

T

P

1

5

T

P

1

5

1

3

2

D51

ST

TH

6003C

WD

51

ST

TH

6003C

W

J21

Fo

ro

J21

Fo

ro

R11

10K

0W

25

5%

R11

10K

0W

25

5%

J

5 J

5

R60

1K

0W

25

5%

R60

1K

0W

25

5%

R38

180A

= 2

10m

VR

38

180A

= 2

10m

V

J

9 J

9

D44

N.M

.D

44

N.M

.

C21

10n

300V

MK

PC

21

10n

300V

MK

P

J1IN

/ O

UT

J1IN

/ O

UT

2

1

3

4 T

1

1

/

2

0

0

2

5

A

T

1

1 /

2

0

0

2

5

A

D29

N.M

.D

29

N.M

.

R35

1K

5 0W

25

5%

R35

1K

5 0W

25

5%

J

1

0

F

I

L

O

T

A

J

1

0

F

I

L

O

T

A

L1 11uH

L1 11uH

Te

rmina

le_O

UT

TO1

Te

rmina

le_O

UT

TO1

J2IN

/ O

UT

J2IN

/ O

UT

T

P

1

2

T

P

1

2

J22

Fo

ro

J22

Fo

ro

C20

100n

63V

MK

TC

20

100n

63V

MK

T

J

6 J

6

R

4

1

1

0

R

5

W

5

%

R

4

1

1

0

R

5

W

5

%

H4

H4

S

T

2

1

1

0

°

C

S

T

2

1

1

0 °

C

C22

10n

300V

MK

PC

22

10n

300V

MK

P

1

3

2

D49

ST

TH

6003C

WD

49

ST

TH

6003C

W

ST1

80

°CS

T1

80

°C

T

P

1

3

T

P

1

3

C

3

2

1

n

5

6

3

0

V

K

P

C

3

2

1

n

5

6

3

0

V

K

P

1

3

2

D46

V.T

.D

46

V.T

.

T

4

T

r

a

s f

o

_

1

/

2

T

4

T r

a

s f

o

_

1

/

2

TP

36

TP

36

D

2

7

N .

M

.

D

2

7 N

.

M .

T

P

1

4

T

P

1

4

1

3

2

D

4

8

V .

T

.

D

4

8 V

.

T .

R37

100K

0W

25

5%

R37

100K

0W

25

5%

1

3

2

D50

N.M

.D

50

N.M

.1

3

2

D47

V.T

.D

47

V.T

.

Q3

BC

337

Q3

BC

337

TP

35

TP

35

H5

H5

JP4

solde

r

JP4

solde

r


Wiring diagram power board


LED

PO T -IN

CADM

CAD1CAD2

VCH ECK

SW

CADA

+5V

17V8

+5V

17V8+5V

+5V

17V8

+5V

+5V

+5V

+ 5 V

+ 5 V

+5V

DR+

TAR+TAR -

S E T

OVER S E T

CC

S TAR T

TA+TA -SH -SH+

VO L T+

FAU L T

COR TO

A L LARM

VR E F

SW

0..10 V

0..2,5 V

R 394K7 0805 1%R 394K7 0805 1%

T P3Tes t_Poin t

T P3Tes t_Poin t

T P2

Tes t_Poin t

T P2

Tes t_Poin t

R 594K7 0805 5%R 594K7 0805 5%

R 51

4K7 0805 1%

R 51

4K7 0805 1%

R 371K 0805 5%

R 371K 0805 5%

R 36

4K7 0805 1%

R 36

4K7 0805 1%

C21100n 50V X7RC21100n 50V X7R

43

5 EN1

U 4BCD4066BC

EN1

U 4BCD4066BC

9 8

U 7D40106U 7D40106

C16

100n 50V X7R

C16

100n 50V X7R

R 30

1K 0805 5%

R 30

1K 0805 5%

1

3

2

D38

BAS40-06

D38

BAS40-06

C710n 50V X7R

C710n 50V X7R

C13100n 50V X7RC13100n 50V X7R

T P4Tes t_Poin t

T P4Tes t_Poin t

1 2

3

D28BAS40-04

D28BAS40-04

89

6 EN1

U 4CCD4066BC

EN1

U 4CCD4066BC

T P8Tes t_Po in t

T P8Tes t_Po in t

C 2 3 2 2 0 n 5 0 V X 7 R

C 2 3 2 2 0 n 5 0 V X 7 R

R 882K0 0805 1%

R 882K0 0805 1%

1 3 1 2

U 7 F 4 0 1 0 6 U 7 F 4 0 1 0 6

T P9Tes t_Po in t

T P9Tes t_Po in t

R 314K7 0805 1%

R 314K7 0805 1%

T P5

Tes t_Poin t

T P5

Tes t_Poin t

R 5710K 0805 5%R 5710K 0805 5%

R 504K7 0805 1%R 504K7 0805 1%

Q7BC807Q7BC807

1

3

2

D36BAV70

D36BAV70

1 2

14

7

U 7A40106U 7A40106

10

98

4

1

1

U 3CLM324DU 3CLM324D

R 271K 0805 5%

R 271K 0805 5%

R 38

4K7 0805 1%

R 38

4K7 0805 1%

Q5BC817Q5BC817

123456789

10111213141516171819202122

J3

70354-301

J3

70354-301

C12100n 50V X7RC12100n 50V X7R

T P 7 T e s t _ P o i n t


5 6

U 7 C 4 0 1 0 6 U 7 C 4 0 1 0 6

C15100n 50V X7RC15100n 50V X7R



R 551K 0805 5%

R 551K 0805 5%

1110

12 EN1

U 4DCD4066BC

EN1

U 4DCD4066BC

12

1314

4

1

1

U 1 D M C 3 3 0 7 4 D U 1 D M C 3 3 0 7 4 D

1 2

3

D22BAS40-04

D22BAS40-04

R 232K0 0805 1%

R 232K0 0805 1%

11 10

U 7E40106U 7E40106

R 323K3 0805 1%

R 323K3 0805 1%

5

67

411

U 3BLM324DU 3BLM324D

C22220n 50V X7R

C22220n 50V X7R

1 2

3

D 2 9 B A S 4 0 - 0 4

D 2 9 B A S 4 0 - 0 4

R 5 8 1 K 0 8 0 5 5 %

R 5 8 1 K 0 8 0 5 5 %

R 174K7 0805 1%

R 174K7 0805 1%

R 33

4K7 0805 1%

R 33

4K7 0805 1%

R 164K7 0805 1%

R 164K7 0805 1%

1

3

2

D25BAS 40-05

D25BAS 40-05

R 5 6 1 0 K 0 8 0 5 5 % R 5 6 1 0 K 0 8 0 5 5 %

1 2

3

D23BAS40-04

D23BAS40-04

12

1314

4

1

1

U 3DLM324DU 3DLM324D

14

712

13 EN1

U 4ACD4066BC

EN1

U 4ACD4066BC

R 4 9 1 0 0 K 0 8 0 5 5 % R 4 9 1 0 0 K 0 8 0 5 5 %

T P1Tes t_Poin t

T P1Tes t_Poin t

R 5339K 0805 1%

R 5339K 0805 1%

R 2910K 0805 5%R 2910K 0805 5%

1

3

2

D 3 7 B A V 7 0 D 3 7 B A V 7 0

3 4

U 7 B 4 0 1 0 6 U 7 B 4 0 1 0 6

R 604K7 0805 5%R 604K7 0805 5%

R 34470K 0805 1%

R 34470K 0805 1%

R 1013K 0805 1%

R 1013K 0805 1%

C40100n 50V X7R

C40100n 50V X7R

R 35 470K 0805 1%

R 35 470K 0805 1%

R 873K0 0805 1%

R 873K0 0805 1%

3

21

4

1

1

U 1AMC33074DU 1AMC33074D

C20100n 50V X7RC20100n 50V X7R

C10100n 50V X7RC10100n 50V X7R

VR E F

R ID DU T

VR E F

VR E F

R ID DU T

VR E F

17V8

17V8

17V8

17V8

17V8

17V8

1 7 V 8 + 5 V

+ 5 V

17V8

COR TO S W

VR E FTA+

TA -

VO L T+

S H -

CC

S TAR T

DR+

S E T

O V E R S E TFAU L T

T A R +

T A R -

S H +

S H -

A L LARM

T P 1 0 T e s t _ P o i n t

T P 1 0 T e s t _ P o i n t

C14100p 50V X7RC14100p 50V X7R

D4G L41GD4G L41G

R 8139R 1206 1%R 8139R 1206 1%

5

42

3

1

2

U 5ALM339U 5ALM339

7

61

3

1

2

U 5BLM339U 5BLM339

R 4 4 7 K 0 8 0 5 1 % R 4 4 7 K 0 8 0 5 1 %

R 150R 0805

R 150R 0805

C1922u 25V A llC1922u 25V A ll

R 413K3 0805 1%

R 413K3 0805 1%

C1822u 25V A ll

C1822u 25V A ll

C11100n 50V X7RC11100n 50V X7R

R 2 6 1 0 K 0 8 0 5 5 %

R 2 6 1 0 K 0 8 0 5 5 %

1 0

98

4

1

1

U 1C M C33074D U 1C M C33074D

R 8 4 K 7 0 8 0 5 1 %

R 8 4 K 7 0 8 0 5 1 %

D39LL4148

D39LL4148

T P 1 1

T e s t _ P o i n t

T P 1 1

T e s t _ P o i n t

R 7 1 K 0 8 0 5 5 %

R 7 1 K 0 8 0 5 5 %

R 621K 0805 5%

R 621K 0805 5%

R 8239R 1206 1%R 8239R 1206 1%

Q4BC807Q4BC807

R 5 2 8 2 K 0 8 0 5 5 %

R 5 2 8 2 K 0 8 0 5 5 %

C810n 50V X7RC810n 50V X7R

R 83680R 0805 1%R 83680R 0805 1%

R 2 0 4 K 7 0 8 0 5 1 %

R 2 0 4 K 7 0 8 0 5 1 %

R 616K8 0805 5%R 616K8 0805 5%

T P13

Tes t_Po in t

T P13

Tes t_Po in t

C610n 50V X7R

C610n 50V X7R

R 6327K 0805 5%

R 6327K 0805 5%

T P14Tes t_Poin t

T P14Tes t_Poin t

1 3

2

D 2 5 V 6 0 W 4 5 %

D 2 5 V 6 0 W 4 5 %

C 3 1 0 n 5 0 V X7R C 3 1 0 n 5 0 V X7R

D42

LL4148

D42

LL4148

R 510K 0805 5%R 510K 0805 5%

R 451K 0805 5%

R 451K 0805 5%

1 2

3

D40BAV99D40BAV99

Q1BC817Q1BC817

R 5 4 4 7 R 0 8 0 5 5 %

R 5 4 4 7 R 0 8 0 5 5 %

C25100n 50V X7RC25100n 50V X7R

T P16

Tes t_Poin t

T P16

Tes t_Poin t

11

1013

3

1

2 U 5DLM339U 5DLM339

R 84200R 0805 1%R 84200R 0805 1%

VFB2

IS EN3 R T /C T

4

VR E F8

COMP1

OU T6

VC

C7

GND5

U 2UC3845AD1U 2UC3845AD1

R 2 2 4 K 7 0 8 0 5 1 % R 2 2 4 K 7 0 8 0 5 1 %

13

2

D1224V 0W 4 5%

D1224V 0W 4 5%

R 141K 0805 5%

R 141K 0805 5%

R 1 1 K 0 8 0 5 5 %

R 1 1 K 0 8 0 5 5 %

R 21N .MR 21N .M

R 123K3 0805 5%

R 123K3 0805 5%

R 1 3 8 K 2 0 8 0 5 1 %

R 1 3 8 K 2 0 8 0 5 1 % T P15

Tes t_Poin t

T P15

Tes t_Poin t

R 111K 0805 5%R 111K 0805 5%

R 464K7 0805 5%

R 464K7 0805 5%

1 2

3

D 4 3 B A S 4 0 - 0 4 D 4 3 B A S 4 0 - 0 4

C 4 1 1 0 0 p 5 0 V X 7 R

C 4 1 1 0 0 p 5 0 V X 7 R

R 4747K 0805 5%R 4747K 0805 5%

R 19

7K5 0805 1%

R 19

7K5 0805 1%

5

67

41

1

U 1BMC33074DU 1BMC33074D

C422n2 50V COGC422n2 50V COG

R 25

2K2 0805 1%

R 25

2K2 0805 1% R 2 8

4 K 7 0 8 0 5 5 % R 2 8

4 K 7 0 8 0 5 5 %

R 241K 0805 5%

R 241K 0805 5%

C9100n 50V X7RC9100n 50V X7R

C 1 1 n 5 0 V X 7 R

C 1 1 n 5 0 V X 7 R

R 7939R 1206 1%R 7939R 1206 1%

R 9100K 0805 1%

R 9100K 0805 1%

D26LL4148D26LL4148

R 64100K 0805 5%R 64100K 0805 5%

R 2 4 K 7 0 8 0 5 5 % R 2 4 K 7 0 8 0 5 5 %

D 3 L L 4 1 48 D 3 L L 4 1 48

Q2MMB F170Q2MMB F170

Q 6 B C 817 Q 6 B C 817

R 63K3 0805 5%R 63K3 0805 5%

C26560p 50V COGC26560p 50V COG

9

814

3

1

2

U 5CLM339U 5CLM339

R 442K7 0805 5%

R 442K7 0805 5%

C 4 1 0 n 5 0 V X 7 R C 4 1 0 n 5 0 V X 7 R

C 2 1 n 5 0 V X7R C 2 1 n 5 0 V X7R

R 8039R 1206 1%R 8039R 1206 1%

R 18820R 0805 1%R 18820R 0805 1%

R 8 6 N . M . R 8 6 N . M .

C17100n 50V X7R

C17100n 50V X7R

R 4333K 0805 5%

R 4333K 0805 5%

R 659K1 0805 1%R 659K1 0805 1%

R 481K 0805 5%

R 481K 0805 5%

3

21

4

1

1

U 3 A L M 3 2 4 D

U 3 A L M 3 2 4 D

C 2 4 1 0 0 n 5 0 V X 7 R

C 2 4 1 0 0 n 5 0 V X 7 R

12

3D11BAV99D11BAV99

Q3MMB F170Q3MMB F170

R 4013K 0805 1%

R 4013K 0805 1%

R 4210K 0805 5%

R 4210K 0805 5%

R 3 2 2 K 0 8 0 5 5 %

R 3 2 2 K 0 8 0 5 5 %

C 5 N . M C 5 N . M

T P12Tes t_Po in t

T P12Tes t_Po in t

- 10 -

4 2 51 3

6

- 11 -

REPAIR GUIDEREPAIR GUIDEREPAIR GUIDEREPAIR GUIDE

EQUIPMENT REQUIRED

(*)The instruments with codes can be supplied by Telwin. The sale price is available on request.

ESSENTIAL INSTRUMENTS1 Dual trace oscilloscope cod. 802401 (*)2 Static load generator cod. 802110 (*)3 Variac 0 - 300v 1500 VA cod. 802402 (*)4 Digital multimeter

USEFUL INSTRUMENTS5 Unsoldering station6 Miscellaneous tools


TROUBLESHOOTING AND REMEDIES1.0 Disassembling the machine Every operation should be carried out in complete safety with the

WARNING: power supply cable disconnected from the mains outlet and should only by done by expert or skilled electrical-mechanical BEFORE PROCEEDING WITH REPAIRS TO personnel.

THE MACHINE READ THE INSTRUCTION MANUAL CAREFULLY.

WARNING:EXTRAORDINARY MAINTENANCE SHOULD BE CARRIED OUT ONLY AND EXCLUSIVELY BY EXPERT OR SKILLED ELECTRICAL-

After completing the repairs, proceed in the reverse order to re-MECHANICAL PERSONNEL.assemble the cover and do not forget to insert the toothed washer on the ground screw.

WARNING:2.0 Cleaning the inside of the machineANY CHECKS CARRIED OUT INSIDE THE Using suitably dried compressed air, carefully clean the MACHINE WHEN IT IS POWERED MAY CAUSE components of the power source since dirt is a danger to parts

SERIOUS ELECTRIC SHOCK DUE TO DIRECT subject to high voltages and can damage the galvanic separation between the primary and secondary.CONTACT WITH LIVE PARTS.To clean the electronic boards we advise decreasing the air pressure to prevent damage to the components.

GENERAL REPAIR INSTRUCTIONS It is therefore important to take special care when cleaning the following partsThe following is a list of practical rules which must be strictly Fan (fig. 2A)adhered to if repairs are to be carried out correctly.Check whether dirt has been deposited on the front and back air A) When handling the active electronic components, the IGBT's vents or has damaged the correct rotation of the blades, if there is and Power DIODES in particular, take elementary antistatic still damage after cleaning replace the fan.precautions (use antistatic footwear or wrist straps, antistatic

working surfaces etc.). Power board (figs. 2A and 2B):B) To ensure the heat flow between the electronic components - rheofores of IGBT's Q6, Q7, Q8, Q9;

and the dissipator, place a thin layer of thermo-conductive - rheofores of recirculating diodes D37, D38;grease (e.g. COMPOUND GREASIL MS12) between the - rheofores of secondary power diodes D46, D47, D48, D49, D51;contact zones. - thermostat ST2 on power transformer;

C) The power resistors (should they require replacement) - tshould always be soldered at least 3 mm above the board. - control board.

D) If silicone is removed from some points on the boards, it should be re-applied. 3.0 Visual inspection of the machineN.B. Use only non-conducting neutral or oximic reticulating Make sure there is no mechanical deformation, dent, or silicones (e.g. DOW CORNING 7093). Otherwise, silicone damaged and/or disconnected connector.that is placed in contact with points at different potential Make sure the power supply cable has not been damaged or (rheophores of IGBT's, etc.) should be left to reticulate before

disconnected internally and that the fan works with the the machine is tested.

machine switched on. Inspect the components and cables for E) When the semiconductor devices are soldered the maximum

signs of burning or breaks that may endanger operation of the temperature limits should be respected (normally 300 C for

power source. Check the following elements:no more than 10 seconds).Main power supply switch (fig. 2A)F) It is essential to take the greatest care at each disassembly Use the multimeter to check whether the contacts are stuck and assembly stage for the various machine parts.together or open. Probable cause: G) Take care to keep the small parts and other pieces that are - mechanical or electric shock (e.g. bridge rectifier or IGBT in dismantled from the machine so as to be able to position them

short circuit, handling under load).in the reverse order when re-assembling (damaged parts should never be omitted but should be replaced, referring to Current potentiometer R49 (fig. 3)the spare parts list given at the end of this manual). Probable cause:

H) The boards (repaired when necessary) and the wiring should - mechanical shock.never be modified without prior authorisation from Telwin. Relay K1, K2 (fig. 3)

I) For further information on machine specifications and Probable cause:operation, refer to the Instruction Manual. - see main power supply switch. N.B. If the relay contacts are

J) WARNING! When the machine is in operation there are stuck together or dirty, do not attempt to separate them and dangerously high voltages on its internal parts so do not touch clean them, just replace the relay.the boards when the machine is live.

Electrolytic capacitors C27,C29, C30, C31 (fig. 3)Probable cause:- mechanical shock;- machine connected to power supply voltage much higher

than the rated value;

°

- remove the current adjustment knob on the front panel of the machine (fig. 1);

- undo the 4 screws attaching the handle to the top cover (fig. 1).- undo the 8 screws fastening the back and front plastic panels; 4

for the cap (fig. 1).- undo the 2 screws attaching the top cover to the base: 1 screw

on each side (fig. 1).- undo the 2 screws fastening the top cover to the metal structure.- slide out the top cover upwards

hermostat ST1 on secondary diode dissipator;

- 12 -


- broken rheophore on one or more capacitor: the remainder powered and therefore the operator is exposed to the danger will be overstressed and become damaged by overheating; of electric shock.

- ageing after a considerable number of working hours; The tests described below can be used to check the operation - overheating caused by thermostatic capsule failure. of the power and control parts of the power source.IGBT's Q6, Q7, Q8, Q9 (fig. 4)Probable cause: 6.1 Preparation for testing- discontinuation in snubber network; A)- fault in driver circuit;- poorly functioning thermal contact between IGBT and

dissipator (e.g. loosened attachment screws: check); B) Set up the multimeter in DC mode and connect the prods to - excessive overheating related to faulty operation. the OUT+ and OUT- bump contacts.Primary diodes D37, D38 (fig. 4) C) Position the potentiometer R49 on maximum (turn Probable cause: clockwise as far as it will go).- excessive overheating related to faulty operation. D) Position the switch SW1 in MMA.Secondary diodes D46, D47, D48, D49, D51 (fig. 4) E) Connect the power supply cable to a single-phase variac Probable cause: with variable output 0-300 Vac.- discontinuation in snubber network;- poorly functioning thermal contact between IGBT and 6.2 Tests for the TECHNOLOGY 175 -210-188CE/GE

dissipator (e.g. loosened attachment screws: check); A) Switch on the variac (initially set to the value 0 V), switch off - faulty output connection. the main switch on the power source and increase the variac Power transformer and filter reactance (fig. 2A) voltage gradually to 230 Vac and make sure:Inspect the windings for colour changes. Probable causes: - the green power supply LED D43 lights up (fig. 3),- power source connected to a higher voltage than 280Vac; - the fan for the power transformer starts up correctly,- ageing after a substantial number of working hours; - the pre-charge relay K1 commutes (fig. 3),- excessive overheating related to faulty operation. - the unloads relay K2 commutes (fig. 3),

- for voltages close to the rated power supply value (230Vac 4.0 Checking the power and signal wiring ±15%) the power source is not in alarm status (yellow LED It is important to check that all the connections are in good D39 off). condition and the connectors are inserted and/or attached NB. if the power source stays in alarm status permanently, correctly. To do this, take the cables between finger and thumb there could be a fault in the control board (in any case, proceed (as close as possible to the fastons or connectors) and pull to make the other tests)outwards gently: the cables should not come away from the B) Make sure the waveform shown on the oscilloscope fastons or connectors. N.B. If the power cables are not tight resembles Fig. A.enough this could cause dangerous overheating.

5.0 Electrical measurements with the machine switched offA) With the multimeter set in diode testing mode check the following components (junction voltages not less than 0.2V):- rectifier bridge D31, D32 (fig. 3);- IGBT's Q6, Q7, Q8, Q9 (absence of short circuits between

collector-gate and between emitter-collector fig. 4); - secondary board diodes D46, D47, D48, D49, D51

between anode and cathode (fig. 4). The secondary diodes can be checked without removing the power board: with one prod on the secondary board dissipator diodes and the other in sequence on the two power transformer outlets;

- MOSFET Q4 (absence of short circuits between drain-gate and drain-source (fig. 4).

B) With the multimeter set in ohm mode check the following components:

N.B. if no signal is present, it may be necessary to replace the - resistor R1: 47ohm (pre-charge fig. 3);

MOSFET Q4 (fig. 3). - resistor R14: 3.3ohm ( fig. 3);

C) With the multimeter set in volt mode make sure that- resistors R44, R45: 22ohm (primary snubber fig. 3);

(fig. 3):- resistor R41: 10ohm (secondary snubber fig. 3);- thermostat continuity test on the power transformer: clean

the resin from the bump contacts of ST2 (J2) and measure the resistance between the two bump contacts, it should be approx. 0 ohm (fig. 2B).

6.0 Electrical measurements with the machine in operationWARNING! Before proceeding with faultfinding, we should

D) Set up the dual trace oscilloscope. Connect the probe remind you that during these tests the power source is CH1(x100) to the Q8 collector and probe CH2 (x10) to the

Set up the oscilloscope with the voltage probe x10 connected between pin 2 (DRAIN) of Q4 and the earth on the case of U5 (fig. 3).

unloads

- voltage between the negative of diode bridge D31 (-) and the catode D11 (-) is equal to +40V ±10%;

- voltage between the negative of diode bridge D31 (-) and the pin 3 of Q2 (+) is equal to +17.8V ±5%;

- voltage between the negative of diode bridge D31 (-) and the pin 3 of U5 (+) is equal to +5V ±5%;

- voltage between the pads V1- and V1+ is equal to +14V ±5% ;

- voltage between the pads V2- and V2+ is equal to +14V ±5%;

- 13 -


FIGURA A

SETTINGS:- PROBE x10;- 5V/Div;- 5 sec/Div.

VERIFY THAT:- FREQUENCY IS

52KHz ±10%;- AMPLITUD IS 22V

±10%.

µ

gate, also of Q8. The earth connections are both made to the emitter of Q8.E) Make sure the waveform displayed on the oscilloscope resembles fig. B.

7.1 Removing the power board (fig. 2A) If the fault is in the power board remove it from the bottom as follows:- with the machine disconnected from the main supply,

disconnect all the wiring connected to the board; - remove the current adjustment knob on the front panel of

the machine ( fig. 1);- remove any bands constraining the board (e.g. on the

power supply cable and connections to primary);- undo the 3 screws fastening the board to the bottom (fig.

2B);

F)

A) Please read the procedure for replacing the IGBT's carefully: (fig. 4).The 4 IGBT's are attached to 2 different dissipators and whenever a replacement is required, both IGBT's should be all replaced. - undo the screws attaching the dissipator to the board to

replace Q6, Q7 (fig. 2B);- undo the screws attaching the dissipator to the board to

replace Q8, Q9 (fig. 2B);H) Make sure the waveform displayed on the oscilloscope - remove the 4 IGBT's and the 2 diodes D37, D38 by resembles fig. C and that the output voltage over OUT+ and unsoldering the rheofores and then clean the solder from OUT - is equal to +100Vdc±10%. the printed circuit bump contacts;

- remove the 2 dissipators from the board;- undo the screws locking the 4 IGBT's.Before making the replacement make sure the components piloting the IGBT's are not also damaged: - with the multimeter set in ohm mode make sure there is no

st rdshort circuit on the PCB between the 1 and 3 bump contacts (between gate and emitter) corresponding to each component;

- alternatively, resistors R42, R43, R46 and R47 could have burst and/or diodes D21, D22, D23 and D24 may be unable to function at the correct Zener voltage (this should have shown up in the preliminary tests);

- clean any irregularity or dirt from the dissipators. If the IGBT's have burst the dissipators may have been irreversibly damaged: in this case they should be replaced;

- apply thermo-conductive grease following the general instructions.- Insert the new IGBT's between the dissipator

I) Switch the power source on again and make sure that, and the spring, taking care not to damage the component following the brief start up time, the machine is not in alarm during assembly (the spring should be inserted under status (the yellow alarm LED D39 is off, fig. 3). N.B. If the pressure on the dissipator so as to lock the component);machine remains in alarm status (and this is not due to a fault in - place the dissipators with the new IGBT's and primary the control board) there could be a fault R9 or D7 (fig. 3). diodes D37 and D38 (WARNING! Make sure there is

insulation between the case of diode D38 and the dissipator) in the PCB bump contacts, placing 4 spacers between the dissipator and the PCB (2 for each dissipator) and fasten them down with the screws (torque wrench setting for screws 1 Nm ±20%);

This is the reference code for requesting a replacement: Telwin may supply boards that are compatible but with different codes.Warning: before inserting a new board check it carefully for damage that may have occurred in transit. When we supply a board it has already been tested and so if the fault is still present after it has been replaced correctly, check the other machine components. Unless specifically required by the procedure, never alter the board trimmers.

- remove the board from the metal structure, lifting it Repeat this test also for Q6, Q7, Q9 (for Q6 and Q7 use the upwards.

differential probe). N.B. for assembly proceed in the reverse order and remember N.B. if the signal is not present there could be a fault in the to insert the toothed washer on the earth screw. IGBT driver circuit (fig. 3) or in the control board (fig. 2A, in this case we recommend replacing the board). G) Set the two-channel oscilloscope ready. Connect the probe CH1 (x100) on the collector of Q8 and the mass on the sender of the same Q8 probe CH2 (x10) on the pin 9 of strip J11. The masses are to be connected together on the sender of Q1. Connect the probe CH2 on the pin 5 of J7 and the mass on pin 6 of the same J7. N.B. In case you wish to measure the two wave shapes together as indicated in the figure it is necessary to use the differential probe (1/20).

7.0 Repairs, replacing the boards If repairing the board is complicated or impossible, it should be completely replaced. The board is identified by a 6-digit code (printed in white on the component side after the initials TW).

- 14 -


SETTINGS:- PROBE CH1 x100;- 100 V/Div;- PROBE CH2 x10;- 10V/Div;- 5 sec/Div.

TIME TOLLERANCES ±20%.

VERIFY THAT:- AMPLITUDE ON CH1

IS 320V ±10%;- POSITIVE

AMPLITUDE ON CH2 IS +19V ±10%;

- NEGATIVE AMPLITUDE ON CH2 IS -2V ±10%.

µ

FIGURA B

SETTINGS:- PROBE CH1 x100- 100V/Div;- P R O B E C H 2

D I F F E R E N T I A L PROBE (1/20);

- 100mV/Div;- 5 sec/Div.



IS 320V ±10%;- P O S I T I V E

AMPLITUDE ON CH2 50mV ±10%.

- N E G A T I V E AMPLITUDE ON CH2 -150mV ±10%

µ

FIGURA C

- solder the terminals taking care not to let the solder run along them;

- on the welding side cut away the protruding part of the C) Set up the multimeter in DC mode and connect the prods to rheofores and check they are not shorted (between the the OUT+ and OUT- bump contacts.gate and emitter in particular). D) Connect the power supply cable to the 230Vac power

supply. B) Please read the procedure for replacing the secondary WARNING! During tests the operator must avoid contact with

the metal parts of the torch because of the presence of board diodes carefully (fig. 4):dangerous, high voltage.The SECONDARY DIODES are attached to the same

dissipator, and when a replacement is required, all of them should be replaced: 1.2 Tests for the TECHNOLOGY 175-210-188CE/GE

- undo the screws attaching the dissipator to the board, to A) Minimum load test:replace diodes D46, D47, D48, D49 and D51;

- remove the secondary diodes unsoldering the rheofores and cleaning any solder from the bump contacts on the board;

- remove the dissipator from the board;- remove the spring locking the diodes; - activate the statico load generator and make sure that:- clean any irregularity or dirt from the dissipator. If the diodes - the waveforms displayed on the oscilloscope resemble

have burst the dissipator may have been irreversibly those in Fig. D;damaged: in this case it should be replaced; - the output current is +6Adc±20%, and the output voltage

- apply thermo-conductive grease following the general is +20.2Vdc±20%.instructions; - deactivate the static load generator and switch off the main

- insert the new diodes between the dissipator and the switch.spring, taking care not to damage the component during assembly (the screw should be inserted under pressure on the dissipator so as to lock the component);

- place the dissipator with the new components in the PCB bump contacts and fasten them down with the screws (torque wrench setting for screws 1 Nm ±20%);

- solder the terminals taking care not to let the solder run along them;

- on the soldering side cut away the protruding part of the rheofores and check they are not shorted (between cathode and anode);

N.B. make sure resistor R41 and capacitor C32 on the snubber have been soldered to the PCB correctly (fig. 3).

C) Please read the procedure for replacing the control board (fig. 3): Whatever fault occurs in the control board, we strongly recommend its replacement without attempts at repair. To remove it, cut and then unsolder from the power board the connector keeping it fixed perpendicular to the PCB, replace it and re-solder the connector.

B) Intermediate load test: Tests should be carried out on the assembled machine before - set up the ohmic load with the switch settings as in the table closing it with the top cover. During tests with the machine in

in fig. E;operation never commute the selectors or activate the ohmic - on the front panel turn the current potentiometer to 60A load contactor.

(approx. half-way);WARNING! Before proceeding to test the machine, we should - start up the ohmic load and make sure that:remind you that during these tests the power source is

- the waveforms displayed on the oscilloscope resemble powered and therefore the operator is exposed to the danger those in Fig. E;of electric shock.

- the output current is equal to +60Adc ±10% and the The tests given below are used to verify power source output voltage is equal to +22.4Vdc ±10%. operation under load.

- switch off the ohmic load.

1.1 Preparation for testing.A) Connect the power source to the static load generator using cables fitted with the appropriate dinse connectors (code 802110).

(1/20), on the pin 5 of J7 (control card) and the mass on pin 6 of the same strip J7.

- set up the static load generator with the switch settings as in the table in Fig. D;

- on the front panel position the current potentiometer at (approx.) half way.

- switch on the main switch;

TESTING THE MACHINE

B) Set the two channel oscilloscope by connecting the probe CH1 (x100) on the collector of Q8 and the mass on the sender of the same Q8. Connect the probe CH2, of differential type

- 15 -


SETTINGS:- PROBE CH1 x100- 100V/Div;- PROBE CH2 differential

probe (1/20)- 100mV- 5 sec/Div.


VERIFY THAT:- AMPLITUDE ON CH1 IS

320V ±10%.- AMPLITUDE ON Ch2 IS

60mV ±10%.

/Div.µ

FIGURA D

11

20

30

40

50

60 Position number

Switch number

using trimmer R48 (fig. 3). - switch off the ohmic load.

C) Rated load test for TECHNOLOGY 175:- set up the ohmic load with the switch settings as in the table

in fig. F;- on the front panel turn the current potentiometer to

maximum (turn clockwise as far as it will go); E) Rated load test for TECHNOLOGY 188CE/GE:- start up the ohmic load and make sure that: - set up the ohmic load with the switch settings as in the table

- the waveforms displayed on the oscilloscope resemble in fig. H;those in fig. F; - on the front panel turn the current potentiometer to

- the output current is equal to +160Adc ±5% and the maximum (turn clockwise as far as it will go);output voltage is equal to +26.4Vdc ±5%; if the output - start up the ohmic load and make sure that:current reading is not 160A ±5%, adjust the current - the waveforms displayed on the oscilloscope resemble using trimmer R48 (fig. 3). those in fig. H;

- switch off the ohmic load. - the output current is equal to +140Adc ±5% and the output voltage is equal to +25.6Vdc ±5%; if the output current reading is not 140A ±5%, adjust the current using trimmer R48 (fig. 3).

- switch off the ohmic load.

D) Rated load test for TECHNOLOGY 210:- set up the ohmic load with the switch settings as in the table

in fig. G;- on the front panel turn the current potentiometer to

maximum (turn clockwise as far as it will go); F) Checking the secondary diode voltages:- start up the ohmic load and make sure that: - set up the dual trace oscilloscope, connecting probe CH1 x

- the waveforms displayed on the oscilloscope resemble 100 to the anode of diode D46 and probe CH2x100 to the those in fig. G; anode of diode D51. Earth connections are both made to

- the output current is equal to +180Adc ±5% and the the secondary dissipator;output voltage is equal to +27.2Vdc ±5%; if the output - remove the multimeter from the OUT+ and OUT- bump current reading is not 180A ±5%, adjust the current contacts;

- 16 -



probe (1/20);- 100mV/Div;- 5 sec/Div.

T I M E T O L L E R A N C E S ±20%.


320V ±10%.- AMPLITUDE ON CH2 IS

120mV ±10%.

µ

FIGURA E

12

22

32

41

51

61

SETTINGS:- PROBE CH1 x100- 100V/Div;- P R O B E C H 2

differential probe (1/20)

- 200mV/Div;- 5 sec/Div.



IS 320V ±10%;- LAMPLITUDE ON

C H 2 I S 1 8 0 m V ±10%.

µ

FIGURA F

13

23

33

43

52

62


probe (1/20); - 200mV/Div;- 5 sec/Div.

T I M E T O L L E R A N C E S ±20%.


320V ±10%;- AMPLITUDE ON CH2 IS

200mV ±10%.

µ

FIGURA G

13

23

33

43

53

62


probe (1/20);- 200mV/Div;- 5V/Div;- 5 sec/Div.

T IME TOLLERANCES ±20%.


320V ±10%;- AMPLITUDE ON CH2 IS

220mV ±10%.

µ

FIGURA H

13

23

33

42

52

62

Position number

Position number

Switch number

Switch number

Position number

Switch number

Position number

Switch number

- set up the static load generator with the switch settings as in the table in fig. F, G or H;

- on the front panel position the current potentiometer to the maximum (turn the knob clockwise as far as it will go) and switch on the main switch;

- activate the static load generator and make sure that the waveforms displayed on the oscilloscope resemble those in fig. I;

- deactivate the static load generator and switch off the main switch.

G) Running time check and closing the machineWith the load status as in fig. F, G or H and the current adjustment potentiometer on maximum, switch on the power source and leave it in operation until the thermostatic capsules trigger (machine in alarm status). Check the correct positioning of the internal wiring and finally re-assemble the machine.

H) Welding testWith the power source set up according to the instructions in the handbook make a test weld at 80A (electrode diameter 2.5 mm). Check the dynamic behaviour of the power source.

- 17 -


SETTINGS:- PROBE CH1 x100- 50V/Div;- PROBE CH2 x100;- 50V/Div;- 5 sec/Div.


VERIFY THAT:- M A X R E V E R S E

AMPLIDUTE ON CH1 AND CH2 DOES NOT EXCEED A 250V.

µ

FIGURA H

ILLUSTRATIONSFIG. 1

NUTSFASTENINGMETALLIC

STRUCTURE

RHEOFORESQ6, Q7

FIG. 2A FIG. 2B

FIG. 4

RHEOFORESQ8, Q9

- 18 -

FIG. 3

NUTS FASTENINGMETALLIC STRUCTURE

SCREWS FASTENINGTOP COVER

POWER SUPPLY LED

CURRENT REGULATIONPOTENTIOMETER

ALARM LED

SCREWSFASTENING

FRONT PANEL

SCREWS FASTENING BACK PANEL

SCREWS FASTENINGHANDLE

SCREWS FASTENINGHANDLE

DINSE SOCKET

POWERTRANSFORMER

DIODESSECONDARYDISSIPATORS

POWER SUPPLYINTERRUPTOR FAN WIRE

CONTROLBOARD

BOTTOMINDUCTANCE

FAN

FILTERCAPACITORS

IGBTDISSIPATORS

DIODES BRIDGEDISSIPATOR

BUMPCONTACTS

THERMOSTATST1 (J1,J2)

Q6, Q7DISSIPATOR

SCREWSFASTENING

SECONDARYDISSIPATOR

SCREWSFASTENING

NUTSFASTENINGMETALLIC

STRUCTURE

Q8, Q9 DISSIPATOR

SCREWSFASTENING

PRIMARYDIODE

D37

PRIMARYDIODE

D38


WELDING PROCEDURE

FUNCTION SELECTOR

BUMPCONTACTS FAN

V1,V2

C29

R14

R49

U5D31, D32 R41K1, K2

Sw1

V1, V2 Q2

D43

D39

C31

C30

K1, K2 R40

R44 R45 Q4 St2

D7,R9 J7

R38

C32

IGBT Q8, Q9

IGBT Q6, Q7

SECONDARY DIODESD46,D47,D48,D49,D51

R48

- 19 -

ELENCO PEZZI DI RICAMBIO - LISTE PIECES DETACHEESSPARE PARTS LIST - ERSATZTEILLISTE - PIEZAS DE REPUESTO

Per richiedere i pezzi di ricambio senza codice precisare: codice del modello; il numero di matricola; numero di riferimento del particolare sull'elenco ricambi.Pour avoir les pieces detachees, dont manque la reference, il faudra preciser: modele, logo et tension de I'appareil; denomination de la piece; numero de matricule.

When requesting spare parts without any reference, pls specify: model-brand and voltage of machine; list reference number of the item; registration number.Wenn Sie einen Ersatzteil, der ohne Artikel Nummer ist, benoetigen, bestimmen Sie bitte Folgendes: Modell-zeichen und Spannung des Geraetes; Teilliste Nuemmer;

TECHNOLOGY 175-210

23

22

25

1

12

13

21

24

15 11 3 17 5 6 10 2 16 18 4 7 8 9

26 27 28 20 14 19


- 20 -

TECHNICAL REPAIR CARD.In order to improve the service, each servicing centre is requested to fill in the technical card on the following page at the end of every repair job. Please fill in this sheet as accurately as possible and send it to Telwin. Thank you in advance for your co-operation!

ELENCO PEZZI DI RICAMBIOPIECES DETACHEESSPARE PARTS LISTERSATZTEILLISTE

PIEZAS DE REPUESTO

REF. REF. REF. REF. REF.


PIEZAS DE REPUESTO


PIEZAS DE REPUESTO


PIEZAS DE REPUESTO


PIEZAS DE REPUESTO

PotenziometroPotentiometrePotentiometerPotentiometerPotenciometroResistenzaResistanceResistorWiederstandResistenciaCondensatoreCondensateurCapacitorKondensatorCapacitorDiodoDiodeDiodeDiodeDiodoRaddrizzatoreRedresseurRectifierGleichrichterRectificadorResistenzaResistanceResistanceWiderstandResistenciaScheda ControlloCarte ControleControl BoardSteuerungskarteTarjeta ControlBjt Tip50Bjt Tip50Bjt Tip50Bjt Tip50Bjt Tip50Bjt Tip122Bjt Tip122Bjt Tip122Bjt Tip122Bjt Tip122

Rele'RelaisRelaisRelaisRelaisInterruttoreInterrupteurSwitchSchalterInterruptorManopola PotenziometroPoignee Pour PotentiometreKnob For PotentiometerPotentiometergriffMalja Por Resist.electr.variableDeviatoreGareurSwitchSchalterInterruptorTermostatoThermostatThermostatThermostatTermostatoCavo Alim.Cable Alim.Mains CableNetzkabelCable Alim.VentilatoreVentilateurFanVentilatorVentiladorInduttanza FiltroInductance FilterFilter InductanceFilter DrosselInduccion FiltroTrasformatore AusiliarioTransformateur AuxiliaireAuxiliary TransformerHilfstransformatorTransformador Auxiliar

InduttanzaInductanceInductanceDrosselInduccionTrasformatore PotenzaTransformateur PuissancePower TransformerLeistungstransformatorTransformador De PotenciaFrontalePartie FrontalFront PanelGeraetefrontFrontalRetroPartie ArriereBack PanelRueckseiteTraseraManicoPoigneeHandleHandgriffManijaPresa DinsePrise DixDinse SocketDinse SteckdoseEnchufe DinseKit MantelloKit CapotCover KitDeckel KitKit Panel De CoberturaKit FondoKit ChassisBottom KitBodenteil KitKit FondoKit Igbt + DiodoKit Igbt + DiodeKit Igbt + DiodeKit Igbt + DiodeKit Igbt + Diodo

Kit Scheda CompletaKit Platine CompleteComplete Control Pcb KitKomplette Steurungskarte KitKit Tarjeta De Controlo Completa

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ELENCO PEZZI DI RICAMBIO - LISTE PIECES DETACHEESSPARE PARTS LIST - ERSATZTEILLISTE - PIEZAS DE REPUESTO

Per richiedere i pezzi di ricambio senza codice precisare: codice del modello; il numero di matricola; numero di riferimento del particolare sull'elenco ricambi.Pour avoir les pieces detachees, dont manque la reference, il faudra preciser: modele, logo et tension de I'appareil; denomination de la piece; numero de matricule.

When requesting spare parts without any reference, pls specify: model-brand and voltage of machine; list reference number of the item; registration number.Wenn Sie einen Ersatzteil, der ohne Artikel Nummer ist, benoetigen, bestimmen Sie bitte Folgendes: Modell-zeichen und Spannung des Geraetes; Teilliste Nuemmer; Registriernummer.

TECHNOLOGY 188CE/GE

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Scheda tecnica di riparazione:Con lo scopo di migliorare il servizio, alla fine di ogni riparazione chiediamo ad ogni Centro Assistenza di compilare e restituire a Telwin la scheda tecnica riportata nella pagina seguente.

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PIEZAS DE REPUESTO

REF. REF. REF. REF. REF.


PIEZAS DE REPUESTO


PIEZAS DE REPUESTO


PIEZAS DE REPUESTO


PIEZAS DE REPUESTO

PotenziometroPotentiometrePotentiometerPotentiometerPotenciometroResistenzaResistanceResistorWiederstandResistenciaCondensatoreCondensateurCapacitorKondensatorCapacitorDiodoDiodeDiodeDiodeDiodoRaddrizzatoreRedresseurRectifierGleichrichterRectificadorResistenzaResistanceResistanceWiderstandResistenciaScheda ControlloCarte ControleControl BoardSteuerungskarteTarjeta ControlBjt Tip50Bjt Tip50Bjt Tip50Bjt Tip50Bjt Tip50Bjt Tip122Bjt Tip122Bjt Tip122Bjt Tip122Bjt Tip122

Rele'RelaisRelaisRelaisRelaisInterruttoreInterrupteurSwitchSchalterInterruptorManopola PotenziometroPoignee Pour PotentiometreKnob For PotentiometerPotentiometergriffMalja Por Resist.electr.variableDeviatoreGareurSwitchSchalterInterruptorTermostatoThermostatThermostatThermostatTermostatoCavo Alim.Cable Alim.Mains CableNetzkabelCable Alim.VentilatoreVentilateurFanVentilatorVentiladorInduttanza FiltroInductance FilterFilter InductanceFilter DrosselInduccion FiltroTrasformatore AusiliarioTransformateur AuxiliaireAuxiliary TransformerHilfstransformatorTransformador Auxiliar

InduttanzaInductanceInductanceDrosselInduccionTrasformatore PotenzaTransformateur PuissancePower TransformerLeistungstransformatorTransformador De PotenciaFrontalePartie FrontalFront PanelGeraetefrontFrontalRetroPartie ArriereBack PanelRueckseiteTraseraManicoPoigneeHandleHandgriffManijaPresa DinsePrise DixDinse SocketDinse SteckdoseEnchufe DinseKit MantelloKit CapotCover KitDeckel KitKit Panel De CoberturaKit FondoKit ChassisBottom KitBodenteil KitKit FondoKit Igbt + DiodoKit Igbt + DiodeKit Igbt + DiodeKit Igbt + DiodeKit Igbt + Diodo

Kit Scheda CompletaKit Platine CompleteComplete Control Pcb KitKomplette Steurungskarte KitKit Tarjeta De Controlo CompletaInduttanza Filtro GeInductance Filter GeGe Filter InductanceGe Filter DrosselInduccion Filtro Ge

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Official servicing centers

Repairing sheetDate:

Inverter :

Serial number:

Company:

Technician:

model

In which place has the inverter been used?

Building yard

Workshop

Others:

Supply:

Power supply

From mains without extension

:From mains with extension m

Mechanichal stresses the machine has undergone to

cription:Des

Dirty grade

Dirty inside the machine

Description:

Rectifier bridge

Electrolytic capacitors

Relais

In-rush limiter resistance

IGBT

Snubber

Secondary diodes

Potentiometer

Others

Kind of failure Component ref.Substitution of primary power board: yes no

Troubles evinced during repair :

TELWIN S.p.A. - Via della Tecnica, 336030 VILLAVERLA (Vicenza) Italy Tel. +39 - 0445 - 858811Fax +39 - 0445 - 858800 / 858801E-mail: [email protected] http://www.telwin.com

Inverter Technology 175 210 188GE

Documents

Transcript of Inverter Technology 175 210 188GE