cod. 988656
TECNICA 140.1 - 142
inver ter
TECNICA 114
CONTENTS PAGE
OPERATION AND WIRING DIAGRAMS................ 2
REPAIR GUIDE...................................................... 9
SPARE PARTS LIST...............................................17
REPAIR SHEET......................................................19
Block diagram 2Analysis of the block diagram 3Illustrations 5Wiring diagrams 6
Equipment required 9General repair instructions 10Troubleshooting and remedies 10Testing the machine 13Illustrations 15
TROUBLESHOOTING
AND REPAIR MANUAL
TROUBLESHOOTING
AND REPAIR MANUAL
TROUBLESHOOTING
AND REPAIR MANUAL
TROUBLESHOOTING
AND REPAIR MANUAL
“reparation no problem !”
TECNICA 114
- 2 -
BLOCK DIAGRAM
OPERATION AND WIRING DIAGRAMSOPERATION AND WIRING DIAGRAMSOPERATION AND WIRING DIAGRAMSOPERATION AND WIRING DIAGRAMS6CU
RR
EN
TTR
AN
SFO
RM
ER
1EM
CFI
LTER
7PO
WER
TR
AN
SFO
RM
ER
19
CU
RR
EN
TP
OTEN
TIO
METER
22
GA
LVA
NIC
SEP
AR
ATIO
N
11
ALIM
EN
TATO
RE
FLY-B
AC
K
12
AU
XIL
IAR
Y
PO
WER
SU
PP
LY
25
PO
WER
SU
PP
LYLED
26
FAN
15
DU
TY
CY
CLE
MA
KER
16AD
DER
17ALA
RM
BLO
CK
2PR
E-C
HA
RG
E
3REC
TIF
IER
BR
IDG
E
4FILT
ER
5CH
OP
PE
R
88SEC
ON
DA
RY
DIO
DE
9IND
UCT
ANCE
OU
TP
UT
14
PR
IMA
RY
CU
RR
EN
TR
EA
DER
AN
DLIM
ITER
13
DR
IVER
10SECO
ND
ARY
EMC
FILT
ERIN
PU
T
11
AU
XIL
IAR
YP
OW
ER
SU
PP
LYTR
IGG
ER
18
ALA
RM
LED
23
t
OV
ER
VO
LTA
GE
SA
FEG
UA
RD
21
IGB
TTH
ER
MO
STA
T
20
MA
XIM
UM
CU
RR
EN
TA
DJU
STM
EN
T
24
UN
DER
VO
LTA
GE
SA
FEG
UA
RD
- 3 -
ANALYSIS OF THE BLOCK DIAGRAMNOTE: Unless indicated otherwise, it should be assumedthat the components are assembled on the power board.
Consisting of:C1, C8, C9, L1.Prevents noise from the machine from being transmittedalong the main power line and vice versa.
Consisting of:K1, R2.Prevents the formation of high transitory currents that coulddamage the main power switch, the rectifier bridge and theelectrolytic capacitors.When the power source is switched on the relay K1 is de-energised, capacitors C2, C3, C4 are then charged by R2.When the capacitors are charged the relay is energised.
Consisting of:D1.Converts the mains alternating voltage into continuouspulsed voltage.
Consisting of:C2, C3, C4.Converts the pulsed voltage from the rectifier bridge intocontinuous voltage.
Consisting of:Q1.Converts the continuous voltage from the filter into a highfrequency square wave capable of piloting the powertransformer.Regulates the power according to the required weldingcurrent/voltage.
Consisting of:T2.The C.T. is used to measure the current circulating in thepower transformer primary and transmit the information toblock 17 (primary current reader and limiter).
Consisting of:T1.Adjusts the voltage and current to values required for thewelding procedure. Also forms galvanic separation of theprimary from the secondary (welding circuit from the powersupply line).
Consisting of:D22Diode D22 converts the current circulating in thetransformer to a single direction, preventing saturation ofthe nucleus, and recirculates the inductance output current(block 9) during the time when the IGBT's are notconducting, bypassing the power transformer (block 7).
Block 1
Block 2
Block 3
Block 4
Block 5
Block 6
Block 7
Block 8
EMC Filter
Pre-charge
Rectifier bridge
Filter
Chopper
Current transformer
Power transformer
Secondary diode
Block 9
Block 10
Block 11
Block 12
Block 13
Block 14
Block 15
Block 16
Block 17
Inductance
Secondary EMC Filter
Auxiliary power supply trigger
Auxiliary power supply
Driver
Primary current reader and limiter
Duty cycle maker
Adder
Alarm Block
Consisting of:L2.Levels the secondary board diodes’output current making itpractically continuous.
Consisting of: C23, C24.Prevents noise from the power source from beingtransmitted through the welding cables and vice versa.
Consisting of:R13, R14, R15, C13Via the resistors, the power source supplies the necessaryvoltage to power block 12 (auxiliary power supply).
Consisting of:D10, C11, Q11, D11Rectifies, filters and stabilises the voltage arriving from thetertiary winding of the power transformer (block 7).
Consisting of:Q6, Q7, D46, D47Picks up the signal arriving from block 15 (duty cycle maker)adjusts it to suit piloting of block 5 (chopper).
Consisting of: D42, D45, R56, C44, R57, R58, R59.Reads the signal from block 6 (current transformer) andscales it down so it can be processed and compared inblocks 15 and 16.
Consisting of:U3, U2B.Processes the information from block 16 (adder) and block14 (primary current reader and limiter) and produces asquare wave with variable duty cycle limiting the primarycurrent to a maximum pre-set value under allcircumstances.
Consisting of:U1D.Gathers all the information from block 14 (primary currentreader and limiter), from block 17 (alarms) and from block19 (current potentiometer), and produces a signal with asuitable voltage for processing by block 15 (duty cyclemaker).
Consisting of:Q3, U1A, U1C.When an alarm is detected the power source output currentis drastically reduced by making direct adjustments to block15 (duty cycle maker) and directly changing the referencesignal obtained from block 19 (current potentiometer).
TECNICA 114
- 4 -
Block 26FanConsisting of:V1.Powered directly by block 12 (a ) andcools the power components.
uxiliary power supply
Block 18
Block 19
Block 20
Block 21
Block 22
Block 23
Block 24
Block 25
Alarm LED
Current potentiometer
Maximum current adjustment
IGBT Thermostat
Galvanic separation
Overvoltage safeguard
Undervoltage safeguard
Power supply LED
Consisting of:D35.It is switched on by block 17 (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 overvoltage.4) Short circuit at output (electrode holder clamp and earth
cable connected to one another or electrode stuck topiece being welded).
Consisting of:R75.This is used to set the reference voltage needed to adjustthe output current: when the potentiometer knob is turnedthe cursor voltage varies, thus varying the current from theminimum to the maximum value.
Consisting of:R70, R71, R72, R73, R74.Used to adjust the maximum cutting current to be suppliedby the power source.
Consisting of:ST1When the temperature of the IGBT dissipator reaches agiven temperature the thermostat cuts in, sending an alarmsignal to block 22 (galvanic separation). It is resetautomatically when this alarm condition is no longerpresent.
Consisting of: ISO1The signal arriving from blocks 21 (IGBT thermostat) isseparated galvanically and sent to block 17 (alarms) fordetection of a possible alarm event.
Consisting of:R40, R41, R42, Q3.If the main supply voltage exceeds the maximum value thissafeguard triggers (a tolerance of approx. ±15% of thepower supply voltage is allowed: outside this range thesafeguard triggers).
Consisting of: R63, R64, U1C, Q8.If the main supply voltage falls below the minimumallowedvalue this safeguard triggers (a tolerance of approx.±15% of the power supply voltage is allowed: outside thisrange the safeguard triggers).
Consisting of:D34.Indicates when the power source is correctly powered andready for use.
TECNICA 114
- 5 -
Power boad
TECNICA 114
ILLUSTRATIONS
(13)DRIVER
(3)RECTIFIER
BRIDGE
(6)CURRENT
TRANSFORMER
(4)FILTER
(1)EMC FILTER
(5)CHOPPER
(7)POWER
TRANSFORMER
(10)SECONDARYEMC FILTER
(8)SECONDARY
DIODE
(2)PRE-CHARGE
(25)POWER
SUPPLY LED
(18)ALARM
LED
(9)INDUCTANCE
(12)AUXILIARY POWER
SUPPLY
(19)CURRENT
POTENTIOMETER
(16)
(17)ADDER
ALARM BLOCK
(15)DUTY CYCLE
MAKER
- 6 -
TECNICA 114
WIRING DIAGRAMS
General wiring diagram
PO
WER
PC
B
10
0/1
15
VO
R2
30
VO
NLY
MO
DELS
WIT
HPO
WER
SU
PPL Y
CH
AN
GE
+J4
+J4
-J4
-J4
J7J7
23
0V
23
0V
11
5V
11
5V
P4
P4
PE
L1N(L
2)
V1
Fan
V1
Fan
J1J1J2J2
OU
T+O
UT+
J3J3
OU
T-O
UT-
541
2
S1O
N/O
FF
541
2
S1O
N/O
FF
- 7 -
TECNICA 114
Wiring diagram power board – power supply
CN
1-9
CN
1-5
CN
1-2
CN
1-9
CN
1-3
CN
1-5
CN
1-8
CN
1-8
CN
1-4
CN
1-4
CN
1-6
CN
1-3
CN
1-2
CN
1-6
RIL
-I
CN
1-6
OU
TN
VA+
B-Q
8
E-Q
5
B-Q
5
CN
1-7
SO
V-T
CN
1-1
OU
TP DC
-
STS
_B
STS
_A
+12V
+12V
+5V
+12V
+5V
+12V
+5V
+12V
+12V
Te
rmo
sta
ti
R17
22
K0805
5%R
17
22
K0805
5%
R19
33
K1206
5%
R19
33
K1206
5%
Vcc
7
VF
B2
Ise
n3
GN
D5
OU
T6
CO
MP
1
VR
EF
8
RT
/CT
4
U1 U
C384
5A
D
U1 U
C384
5A
D
R58
120R
0805
5%R
58
120R
0805
5%
R5
33
K1206
5%
R5
33
K1206
5%
R14
33
K1206
5%
R14
33
K1206
5%
R1
33
K1206
5%
R1
33
K1206
5%
D24
10V
0W4
5%D
24
10V
0W4
5%
R13
4K
70805
5%R
13
4K
70805
5%D
28
BYG
20G
D28
BYG
20G
1 2
3D
38
BA
V99
D38
BA
V99
R15
100R
0805
5%
R15
100R
0805
5%
R26
14
K7
0805
1%R
26
14
K7
0805
1%
R6
100R
0805
5%R
6100R
0805
5%
D15
18V
0W4
5%D
15
18V
0W4
5%
R9
680R
0805
5%
R9
680R
0805
5%
C26
1u
25V
Z5U
C26
1u
25V
Z5U
R47
1K
0805
5%R47
1K
0805
5%
1
2 3
Q7
BC
807
Q7
BC
807
R32
10
K0805
5%
R32
10
K0805
5%
D29
18V
0W4
5%
D29
18V
0W4
5%
C11
1u
25V
Z5U
C11
1u
25V
Z5U
D37
4V
70W
42%
D37
4V
70W
42%
D19
BYG
20G
D19
BYG
20G
D16
18V
0W4
5%
D16
18V
0W4
5%
R16
1K
0805
5%
R16
1K
0805
5%
R59
470R
0805
5%R
59
470R
0805
5%
D25
BYG
20G
D25
BYG
20G
R48
47R
08
05
5%R
48
47R
08
05
5%
R42
1K
0805
5%R42
1K
0805
5%
R28
680R
0805
5%R
28
680R
0805
5%
R52
3K
31206
5%R
52
3K
31206
5%
R20
680R
0805
5%
R20
680R
0805
5%
D22
10V
0W4
5%D
22
10V
0W4
5%
D23
BYG
20G
D23
BYG
20G
1
23
Q2
BC
817
Q2
BC
817
R33
220
K0805
5%R
33
220
K0805
5%
R2
200R
1T
0W5
10%
R2
200R
1T
0W5
10%
R43
10
K0805
5%R
43
10
K0805
5%
D18
BYG
20G
D18
BYG
20G
12
3
D7
BA
V99
D7
BA
V99
C3
100p
50
VX
7R
C3
100p
50V
X7R
D27
BYG
20G
D27
BYG
20G
R50
2K
20805
5%R
50
2K
20805
5%R
22
2K
20805
5%
R22
2K
20805
5%
R61
10R
12
06
5%R
61
10R
12
06
5%
1
2 3
Q6
BC
807
Q6
BC
807
R3
100R
0805
5%R
3100R
0805
5%
1
23
Q1
BC
817
Q1
BC
817
D17
18V
0W4
5%
D17
18V
0W4
5%R
56
120R
0805
5%R
56
120R
0805
5%
12
13
14
4 11
U2D
LM324
U2D
LM324
R49
1K
1206
5%R49
1K
1206
5%
D26
BYG
20G
D26
BYG
20G
R38
2K
20805
5%R
38
2K
20805
5%
D30
18V
0W4
5%
D30
18V
0W4
5%
D4
24V
0W4
5%D
424V
0W4
5%
R44
4K
70805
5%R
44
4K
70805
5%
C14
100n
50V
X7R
C14
100n
50V
X7R
R30
4K
70805
5%R
30
4K
70805
5%
R24
33
K1206
5%
R24
33
K1206
5%
R27
10
K0805
5%R
27
10
K0805
5%R
11
4K
70805
5%R
11
4K
70805
5%
R57
6K
85W
5%R57
6K
85W
5%
Q4
IRFD
110
Q4
IRFD
110
12
3
D6
BA
V99
D6
BA
V99
C31
1u
25V
Z5U
C31
1u
25V
Z5U
R51
3K
31206
5%R
51
3K
31206
5%
R25
27R
1W5%
R25
27R
1W5%
12
3
D5
BA
V99
D5
BA
V99
R34
1K
0805
5%
R34
1K
0805
5%
R53
1K
0805
5%R53
1K
0805
5%
R10
470R
0805
5%R
10
470R
0805
5%
C13
100n
50V
X7R
C13
100n
50V
X7R
1
2 3
Q9
BC
807
Q9
BC
807
C2
100p
50V
X7R
C2
100p
50V
X7R
C10
100n
50V
X7R
C10
100n
50V
X7R
10 9
8
4 11
U2C
LM324
U2C
LM324
3 21
4 11
U2A
LM324
U2A
LM324
C23
100n
50V
X7R
C23
100n
50V
X7R
R7
10
K0805
5%R
710
K0805
5%
R36
2K
20805
5%R
36
2K
20805
5%
C29
100u
35V
All
C29
100u
35V
All
R21
14
K7
0805
1%R
21
14
K7
0805
1%
R55
470R
0805
5%R
55
470R
0805
5%
R31
100
K0805
5%
R31
100
K0805
5%
R29
22
K1206
5%R
29
22
K1206
5%
C19
100n
50V
X7R
C19
100n
50V
X7R
R54
10R
12
06
5%
R54
10R
12
06
5%
12
3
D1
BA
V99
D1
BA
V99
D20
BYG
20G
D20
BYG
20G
18
654 3
T1
TI1
20023
T1
TI1
20023
C24
1n
50V
NPO
C24
1n
50V
NPO
R62
1K
0805
5%R62
1K
0805
5%C
44u7
16V
TA
NC
44u7
16V
TA
N
C12
10n
50V
X7R
C12
10n
50V
X7R
214 3
ISO
1T
LP
621
ISO
1T
LP
621
D3
4V
70W
45%
D3
4V
70W
45%
5 67
4 11
U2
BLM
324
U2
BLM
324
C5
1n
50V
NPO
C5
1n
50V
NPO
12
3
D2
BA
V99
D2
BA
V99
1 2 3 4 5 6 7 8 9 10
11
12
Te
st P
oin
t
12
Fo
r iP
asso
2.5
4mm
Te
st P
oin
t
12
Fo
r iP
asso
2.5
4mm
R12
10
K0805
5%R
12
10
K0805
5%
C6
100n
50
VX
7R
C6
100n
50
VX
7R
1
23
Q3
BC
817
Q3
BC
817
R23
10
KL
in0W
220%
R23
10
KL
in0W
220%
C9
1n
50V
NPO
C9
1n
50V
NPOC
7100n
50V
X7R
C7
100n
50V
X7R
- 8 -
TECNICA 114
Wiring diagram power board – driver / control
4 2 51 3
6
- 9 -
TECNICA 114
REPAIR GUIDEREPAIR GUIDEREPAIR GUIDEREPAIR GUIDE
EQUIPMENT REQUIRED
(*)The instruments with codes can be supplied by Telwin. The sale price is available on request.
ESSENTIAL INSTRUMENTS
USEFUL INSTRUMENTS
1 Dual trace oscilloscope cod. 802401 (*)2 Static load generator cod. 802110 (*)3 Variac 0 - 300v 1500 VA cod. 802402 (*)4 Digital multimeter
5 Unsoldering station6 Miscellaneous tools
WARNING:
WARNING:
WARNING:
BEFORE PROCEEDING WITH REPAIRS TO THEMACHINE READ THE INSTRUCTION MANUALCAREFULLY.
EXTRAORDINARY MAINTENANCE SHOULD BECARRIED OUT ONLY AND EXCLUSIVELY BYE X P E R T O R S K I L L E D E L E C T R I C A L -MECHANICAL PERSONNEL.
ANY CHECKS CARRIED OUT INSIDE THEMACHINE WHEN IT IS POWERED MAY CAUSESERIOUS ELECTRIC SHOCK DUE TO DIRECTCONTACTWITH LIVE PARTS.
GENERAL REPAIR INSTRUCTIONS
TROUBLESHOOTING AND REMEDIES
The following is a list of practical rules which must be strictlyadhered to if repairs are to be carried out correctly.A) When handling the active electronic components, the
IGBT's and Power DIODES in particular, takeelementary antistatic precautions (use antistaticfootwear or wrist straps, antistatic working surfacesetc.).
B) To ensure the heat flow between the electroniccomponents and the dissipator, place a thin layer ofthermo-conductive grease (e.g. COMPOUNDGREASIL MS12) between the contact zones.
C) The power resistors (should they require replacement)should always be soldered at least 3 mm above theboard.
D) If silicone is removed from some points on the boards, itshould be re-applied.
Use only non-conducting neutral or oximicreticulating silicones (e.g. DOW CORNING 7093).Otherwise, silicone that is placed in contact with pointsat different potential (rheophores of IGBT's, etc.) shouldbe left to reticulate before the machine is tested.
E) When the semiconductor devices are soldered themaximum temperature limits should be respected(normally 300 C for no more than 10 seconds).
F) It is essential to take the greatest care at eachdisassembly and assembly stage for the variousmachine parts.
G) Take care to keep the small parts and other pieces thatare dismantled from the machine so as to be able toposition them in the reverse order when re-assembling(damaged parts should never be omitted but should bereplaced, referring to the spare parts list given at theend of this manual).
H) The boards (repaired when necessary) and the wiringshould never be modified without prior authorisationfromTelwin.
I) For further information on machine specifications andoperation, refer to the Instruction Manual.
J) When the machine is in operation there aredangerously high voltages on its internal parts so do nottouch the boards when the machine is live.
Every operation should be carried out in complete safetywith the power supply cable disconnected from the mainsoutlet and should only by done by expert or skilledelectrical-mechanical personnel.- undo the 4 screws attaching the handle to the top cover
( );- undo the 2 screws fastening the two plastic shells to the
base:1 screw on each side (- undo the 2 screws attaching the handle to the base: 1
screw on each side ( );- on the top cover undo the nut for the earth connection
(J7);- slide out the top cover upwards ( );- undo the two screws fastening the power board to the
base.After completing the repairs, proceed in the reverse order tore-assemble the cover and do not forget to insert thetoothed washer on the ground screw.
Using suitably dried compressed air, carefully clean thecomponents of the power source since dirt is a danger toparts subject to high voltages and can damage the galvanicseparation between the primary and secondary. To cleanthe electronic boards we advise decreasing the air pressureto prevent damage to the components. It is thereforeimportant to take special care when cleaning the followingparts:
Check whether dirt has been deposited on the front andback air vents or has damaged the correct rotation of theblades, if there is still damage after cleaning replace the fan.
Make sure there is no mechanical deformation, dent, ordamaged and/or disconnected connector. Make sure thepower supply cable has not been damaged or disconnectedinternally and that the fan works with the machine switchedon. Inspect the components and cables for signs of burningor breaks that may endanger operation of the power source.Check the following elements:
Use the multimeter to check whether the contacts are stucktogether or open.Probable cause:- mechanical or electric shock (e.g. bridge rectifier or
IGBT in short circuit, handling under load).
Probable cause:- mechanical shock.
Probable cause:- see main power supply switch. If the relay contacts
are stuck together or dirty, do not attempt to separatethem and clean them, just replace the relay.
N.B.
WARNING!
fig.1
fig.1);
fig.1
fig.1
N.B.
1.0 Disassembling the machine
2.0 Cleaning the inside of the machine
3.0 Visual inspection of the machine
Fan (fig.2A)
Power board figs.2A and 2B
Main power supply switch (fig.2A)
Current potentiometer R75 (fig.3)
Relay K1 (fig.3)
( ):
°
- rheofores of IGBT Q1;- rheofores of secondary power diode D22;- thermostat ST1 on the IGBT;- opto-coupler ISO1.
- 10 -
TECNICA 114
Electrolytic capacitors C2,C3 (fig.3)
IGBT's Q1 (fig. 4)
Secondary diodes D22 (fig.4)
Power transformer and filter reactance (fig. 2A)
6.1 Preparation for testing
6.2 Scheduled tests for theTECNICA 114 at low voltage
Probable cause- mechanical shock;- machine connected to power supply voltage much
higher than the rated value;- broken rheophore on one or more capacitor: the
remainder will be overstressed and become damagedby overheating;
- ageing after a considerable number of working hours;- overheating caused by thermostatic capsule failure.
Probable cause:- discontinuation in snubber network;- fault in driver circuit;- poorly functioning thermal contact between IGBT and
dissipator (e.g. loosened attachment screws:check);- excessive overheating related to faulty operation.
Probable cause:- discontinuation in snubber network;- poorly functioning thermal contact between IGBT and
dissipator (e.g. loosened attachment screws:check);- faulty output connection.
Inspect the windings for colour changes.Probable causes:- power source connected to a higher voltage than
280Vac;- ageing after a substantial number of working hours;- excessive overheating related to faulty operation.
It is important to check that all the connections are in goodcondition and the connectors are inserted and/or attachedcorrectly. To do this, take the cables between finger andthumb (as close as possible to the fastons or connectors)and pull outwards gently: the cables should not come awayfrom the fastons or connectors. If the power cables arenot tight enough this could cause dangerous overheating.In particular, on the power board it is necessary to makesure all the wiring is inserted correctly into thecorresponding connectors or fastons. Also make sure thatthe connections to the dinse sockets are attached correctlyto the power board.
A) With the multimeter set in mode checkthe following components (junction voltages not less than0.2V):- rectifier bridge D1 );- IGBT's Q1 (absence of short circuits between collector-
gate and between emitter-collector );- secondary board diodes D22 between anode and
cathode ( ).The secondary diodes can be checkedwithout removing the power board: with one prod on thesecondary board dissipator diodes and the other insequence on the two power transformer outlets;
B) With the multimeter set in ohm mode check the followingcomponents:- resistor R2:47ohm (pre-charge );- resistors R3, R4:22ohm (primary snubber );- resistor R22:10ohm (secondary snubber );- thermostat continuity test on IGBT dissipator: clean the
resin from the bump contacts for ST1(A,B) and measurethe resistance over these two bump contacts, it shouldbe approx 0 ohm ( ).
Before proceeding with troubleshooting, weshould remind you that during these tests the power sourceis powered and therefore the operator is exposed to thedanger of electric shock.The tests described below can beused to check operation of the power and control parts ofthe power source.
A) Set up a multimeter in DC volt mode and connect theprods to the OUT+ and OUT- bump contacts.B) Position the potentiometer R75 to maximum (clockwiseas far as it will go). to check correct operation of thecontrol circuit without powering the power board werecommend carrying out the test given at point 6.2,otherwise pass to the test at point 6.3.
A) Between the cathode of diode D10 (+) and the anode ofdiode D11(-) insert a stabilised power supply that is able tosupply 40Vdc 500mA.B) Set up the oscilloscope with the voltage probe x100connected between the gate of Q1 and the earth on theemitter, also of Q1 .C) Switch on the stabilised power supply (initially set to 0V)and gradually increase the generated voltage until itreaches 40Vdc.D) Make sure the waveform shown on the oscilloscoperesembles . if the signal is not present it may benecessary to replace component Q1 or, alternatively, thedriver circuit U3, Q6 and Q7 ( ).E) Set up a multimeter in volt mode and make sure that (
):- the voltage over pins 2 and 1 of J8 is equal to +23V ±5%;- the voltage over pins 5 and 1 of J8 is equal to +5Vdc
±5%;- the voltage over pins 4 and 1 of J8 is equal to +500mVdc
±5%;- the voltage over pins 8 and 1 of J8 is equal to 0Vdc.
4.0 Checking the power and signal wiring
5.0 Electrical measurements with the machineswitched off
6.0 Electrical measurements with the machine inoperation
N.B.
diode testing
(fig.3
fig.4
fig. 4
fig.3fig.3
fig.3
fig.2B
WARNING!
N.B.
(fig.3)
fig. A N.B.
fig.3fig.
3
(No C3 on 230V version ofTecnica 114):
- 11 -
TECNICA 114
FIGURE A
SETTINGS:
· PROBE CH1 x10;
· 5 V/Div;
· 10 sec/Div.
· :
60KHz ±10%.
· POSITIVE
AMPLITUDE IS
+16V ±10%;
· NEGATIVE
AMPLITUDE IS
-5V ±10%.
µ
VERIFY THAT:
THE FREQUENCY IS
6.3 Scheduled tests for theTECNICA 114 (230V)
6.4 Scheduled tests for theTECNICA 114 (115V)
7.1 Removing the power board (fig.2A)
A) Disconnect the stabilised power supply from the powerboard.B) Set up the dual trace oscilloscope. Connect probe CH2(x100) to the collector of Q1 and probe CH1 (x10) to thegate, also of Q1. The earth terminals are connectedtogether to the emitter of Q1.C) Connect the power supply cable to a single phasevariac with variable output 0-300Vac.D) Switch on the variac (initially set to 0V), close the mainpower supply switch on the power source and graduallyincrease the voltage generated by the variac until it reaches230Vac then make sure that:- the green power supply LED D34 lights up ( );- the fan starts to turn for the power transformer;- pre-charge relay K1 closes ( );- for voltages close to the rated power supply value
(230Vac ±15%) the power source does not signal analarm (yellow LED D35 off).
if the alarm persists in the power source this could bedue to a fault in the control components (in any caseproceed to make further tests).E) Make sure the waveform shown on the oscilloscoperesembles . if the signal is not present it may benecessary to replace component Q1 or, alternatively, thedriver circuit U3, Q6 and Q7 ( ).
F) Set up a multimeter in volt mode and make sure that ():
- the voltage over pins 2 and 1 of J8 is equal to +23Vdc±5%;
- the voltage over pins 5 and 1 of J8 is equal to +5Vdc±5%;
- the voltage over pins 4 and 1 of J8 is equal to +500mVdc±5%;
- the voltage over pins 8 and 1 of J8 is equal to 0Vdc;- the output voltage over OUT+ and OUT- is equal to
+80Vdc ±10%.G) Set up the dual trace oscilloscope. Connect the voltageprobe x100 between the gate of Q1 and the earth to theemitter, also of Q1 ( ). Probe CH2 (x10) to the rheoforeof R55 towards C11 and the earth to the anode of D11.H) Make sure the waveform shown on the oscilloscoperesembles .
I) Switch the power source off and on again and make surethat, after the transitory switch-on time, there is no alarm(yellow alarm LED D12 is off ) If an alarm persists(and is not caused by a fault in the control board) there couldbe a fault in the opto-coupler ISO1 ( ).
Power the power source at the rated voltage of115Vac. In this case the tests are exactly the same as thosefor the Tecnica 114 (230V) and can be carried out in thesame way.
If the fault is in the power board remove it from the bottom asfollows:- 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 ( );- remove any bands constraining the board (e.g. on the
power supply cable and connections to primary);- from the welding side undo the two screws fastening the
dinse sockets to the printed circuit board ( ).- undo the 2 screws fastening the board to the bottom (
).- undo the 2 screws fastening the board to the front and
back on the inside ( ).- after removing the screws, lift the board upwards to
remove it from the bottom of the machine.to re-assemble, proceed in the reverse order,
remembering to insert the toothed washers on the earthscrews.
fig.3
fig.3
N.B.
fig. B N.B.
fig.3
fig.3
fig. 3
fig.C
fig.3 . N.B.
fig.3
WARNING!
fig.1
fig.2Bfig.
2B
fig.2B
N.B.
7.0 Repairs, replacing the boardsIf repairing the board is complicated or impossible, it shouldbe completely replaced. The board is identified by a 6-digitcode (printed in white on the component side after theinitials TW). This is the reference code for requesting areplacement:Telwin may supply boards that are compatiblebut with different codes.
before inserting a new board check it carefully fordamage that may have occurred in transit.When we supplya board it has already been tested and so if the fault is stillpresent after it has been replaced correctly, check the othermachine components. Unless specifically required by theprocedure, never alter the board trimmers.
Warning:
- 12 -
TECNICA 114
FIGURE B
SETTINGS :
· PROBE CH1 x10;
· 10 V/Div;
· PROBE CH2 x100;
· 200 V/Div;
· 5 sec/Div.
TIME TOLLERANCES:
±20%.
· AMPLITUDE CH2
IS 320V ±10%;
· POSITIVE
AMPLITUDE CH1
IS +18V ±10%;
· NEGATIVE
AMPLITUDE CH1
IS -10V ±10%.
µ
VERIFY THAT
FIGURE C
SETTINGS:
· PROBE CH1 x100;
· 200V/Div;
· PROBE CH2 x10;
· 500mV/Div;
· 5 sec/Div.
TIME TOLLERANCES:
±20%.
· AMPLITUDE CH1 IS
640V ±10%;
· AMPLITUDE CH2 IS
500mV ±50%;
µ
VERIFY THAT
A) Take special note of the procedure for replacing theIGBT (fig. 4):
fig.2B
ohms
B) Take special note of the procedure for replacing thesecondary diodes (fig. 4):
N.B.fig.3
WARNING!
WARNING!
A) Minimum load test:
fig.D
fig.D
- to replace the IGBT undo the screws fastening thedissipator to the board ( );remove IGBT Q1 by unsoldering the rheofores and alsoremove the solder from the bump contacts on the PCB;
- remove the dissipator from the board;- undo the screws holding the IGBT.Before proceeding with the replacement make sure that theparts piloting the IGBT are not damaged as well:- with the multimeter set on check the PCB to make
sure there is no short circuit between the 1st and 3rdbump contacts (between gate and emitter)corresponding to each component;
- alternatively, resistors R8 and R9 could have blownand/or diodes D8 and D9 may be unable to work at acorrect Zener voltage (this should have been detected inthe preliminary tests);
- clean any irregularities or dirt from the dissipator. If theIGBT module has blown the dissipator may beirreparably damaged: in such a case it should bereplaced;
- apply thermoconductive paste following the generalinstructions;
- attach the new IGBT to the dissipator with the screw(torque wrench setting 1 Nm ±20%);
- place the dissipator with the new IGBT on the bumpcontacts of the PCB, interposing, and attach it with thescrews (torque wrench setting 1 Nm ±20%);
- solder the terminals taking care not to let the solder runalong them;
- on the solder side cut the protruding part of therheofores and make sure they have not shorted(between the gate and emitter in particular).
- undo the screws fastening the dissipator to the board;- remove the secondary diodes by unsoldering the
rheofores and also remove the solder from the bumpcontacts on the PCB;
- remove the dissipator from the board;- remove the springs locking the diode;- clean any irregularities or dirt from the dissipator. If the
diode has blown the dissipator may have beenirreparably damaged: in such a case it should bereplaced;
- apply thermoconductive paste following the generalinstructions;
- insert the new diode between the dissipator and thespring, taking care not to damage the component duringassembly (the spring should be inserted by pressure onthe dissipator in order to lock the component);
- place the dissipator with the new component on thebump contacts of the PCB, and attach it with the screws(torque wrench setting 1 Nm ±20%);
- solder the terminals taking care not to let the solder runalong them;
- on the soldering side cut the protruding part of therheofores and make sure they have not shorted(between cathode and anode).
make sure that resistor R22 and capacitor C22 of thesnubber are soldered correctly to the PCB ( ).
Tests should be carried out on the assembled machinebefore closing it with the top cover. During tests with themachine in operation never commute the selectors oractivate the ohmic load contactor.
Before proceeding to test the machine, weshould remind you that during these tests the power sourceis powered and therefore the operator is exposed to thedanger of electric shock.The tests given below are used to verify power sourceoperation under load.
A) Connect the power source to the static load generator(code 802110) using cables fitted with the appropriate dinseconnectors.B) Set up the dual trace oscilloscope. Connect the voltageprobe x100 between the gate of Q1 and the earth to theemitter, also of Q1. Probe CH2 (x10) to the rheofore of R55towards C11 and the earth to the anode of D11.C) Set up a multimeter in DC volt mode and connect theprods to the OUT+ and OUT- bump contacts.D) Connect the power supply cable to the main 230Vacpower supply.
during testing prevent contact with the metalpart of the torch because of the presence of high voltagesthat are hazardous to the operator.
- set up the ohmic load with the switch settings as in thetable in ;
- on the front panel turn the current potentiometer tominimum (turn anti-clockwise as far as it will go);
- switch on at the main switch;- start up the ohmic load and make sure that:
- the waveforms displayed on the oscilloscoperesemble those in ;
- the output current is equal to +9Adc ±5% and theoutput voltage is equal to +15Vdc ±5%;
- switch off the ohmic load and switch off the main switch.
-
1.1 Preparation for testing
1.2 Scheduled tests for theTECNICA 114 (230V)
TESTINGTHE MACHINE
- 13 -
TECNICA 114
SETTINGS:
· PROBE CH1 x 100
· 200V/Div;
· PROBE CH2 x10;
· 500mV/Div;
· 5 /Div.
TOLERANCES:
· FOR TIME 20%.
· PEAK AMPLITUDE
CH1 600V 10%.
· PEAK AMPLITUDE
CH2 900mV 30%.
µsec
±
±
VERIFY THAT:
FIGURE D
Posizione commutatore
Numero commutatore11
20
3 4 5 60 0 0 0
B) Intermediate load test:
fig.E
fig.E
C) Rated load test:
fig.F
fig.F
fig.5
D) Checking the secondary diode voltages:
fig.F
fig.H
E) Running time check and closing the machinefig. F
F) Welding test
- set up the ohmic load with the switch settings as in thetable in ;
- on the front panel turn the current potentiometer to 40A(approx.Half-way);
- switch on at the main switch;- start up the ohmic load and make sure that:
- the waveforms displayed on the oscilloscoperesemble those in ;
- the output current is equal to +40Adc ±10% and theoutput voltage is equal to +21.6Vdc ±10%;
- switch off the ohmic load and switch off the main switch.
- set up the static load generator with the switch settingsas in the table in ;
- on the front panel turn the current potentiometer tomaximum (turn clockwise as far as it will go);
- to the maximum (turn the knob clockwise as far as it willgo) and switch on the main switch;
- activate the static load generator and make sure that:- the voltage waveforms on the oscilloscope display
resemble those in ;- the output current is equal to 75Adc ±5% and the
output voltage is equal to +23.6Vdc ±5%; if theoutput current reading is not 75A ±5%, adjust thecurrent using jumpers JP1, JP2 and JP3 ( ).
- switch off the ohmic load and switch off the main switch
- set up the dual trace oscilloscope by connecting probesCH1 and CH2 x100 to the two secondary outputs of thepower transformer. The earth terminals are connectedtogether to the secondary dissipator;
- remove the multimeter from the OUT+ and OUT- bumpcontacts;
- set up the ohmic load with the switch settings as in thetable in ;
- switch on at the main switch;- on the front panel turn the current potentiometer to
maximum (turn clockwise as far as it will go);- start up the ohmic load and make sure the waveforms;- displayed on the oscilloscope resemble those in ;- switch off the ohmic load and switch off the main switch.
With the load status as in and the current adjustmentpotentiometer on maximum, switch on the power sourceand leave it in operation until the thermostatic capsulestrigger (machine in alarm status). Check the correctpositioning of the internal wiring and finally re-assemble themachine.
With the power source set up according to the instructionsin the handbook make a test weld at 40¸70A (electrodediameter 2.5 mm). Check the dynamic behaviour of thepower source.
1.3 Tests for theTECNICA 114 (115V)Power the power source at the rated voltage of
115Vac. In this case the tests are exactly the same as thosefor the TECNICA 114 (230V) and can be carried out in thesame way.
WARNING!
- 14 -
TECNICA 114
FIGURE F
12
22
32
42
52
61
SETTINGS:
· PROBE
· 200V/Div;
· PROBE CH2 x10;
· 1V/Div;
· 5 sec/Div.
TIME TOLLERANCES
±20%.
±
±2
CH1 x100
VERIFY THAT:
µ
· PEAK AMPLITUDE
CH1 680V 10%.
· PEAK AMPLITUDE
CH2 4.2V 0%.
Position of switch
Switch number
FIGURE G
SETTINGS:
· PROBE
· 50V/Div;
· PROBE CH2 x100;
· 5V/Div;
· 5 sec/Div.
TIME TOLLERANCES
±20%.
· REVERSE
AMPLITUDE CH1
AND CH2 DOES NOT
EXCEED
CH1 x100
250V.
VERIFY THAT
µ
FIGURE E
position switch
number switch11
21
31
41
51
61
SETTINGS:
· PROBE
· 200V/Div;
· PROBE CH2 x10;
· 1V/Div;
· 5 sec/Div.
TIME TOLLERANCES
±20%.
±
±
CH1 x100
VERIFY THAT:
µ
· PEAK AMPLITUDE
CH1 680V 10%.
· PEAK AMPLITUDE
CH2 2.5V 30%.
fig. 1
fig. 2A
- 15 -
TECNICA 114
SCREWS FASTENINGTOP COVER
POWER SUPPLY LED
CURRENT REGULATIONPOTENTIOMETER
ALARM LED
SCREWSFASTENING FRONT PANEL
SCREWS FASTENINGBACK PANEL
SCREWSFASTENING
HANDLE
DINSE SOCKET
ILLUSTRATIONS
POWERTRANSFORMER
SECONDARYDISSIPATORS
POWER SUPPLYINTERRUPTOR FAN WIRE
BOTTOM INDUCTANCEFAN
FILTERCAPACITORS
PRIMARYDISSIPATORS
DIODES BRIDGEDISSIPATOR
- 16 -
fig. 3
fig. 2B
DISSIPATORSFOR DIODES
DISSIPATORSFOR IGBT
THERMOSTATST1
TECNICA 114
BUMPCONTACTSTHERMOSTAT
ST1
RHEOFORESQ1
SCREWSFASTENING
DINSESOCKETS
IGBT DISSIPATORSCREWS FASTENING
Q1
SECONDARY DISSIPATORSCREWS
FASTENING
BUMP CONTACTSFAN
V1+,V1-
RHEOFORESD22
C2 U3Q1 D1 U2
R75
D34
ISO
R3, R4
D22
R55K1
D35
R2 Q11 J8 D11 U1
C22, R22
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 numberWenn Sie einen Ersatzteil, der ohne Artikel Nummer ist, benoetigen, bestimmen Sie bitte Folgendes: Modell-zeichen und Spannung des Geraetes; Teilliste Nuemmer; Registriernummer
Por pedir una pieza de repuesto sin referencia precisar: modelo-marca e tension de la maquina; numero di riferimento de lista; numero di matricula
- 17 -
Esploso macchina, Dessin appareil, Machine drawing, Explosions Zeichnung des Geräts, Diseño seccionado maquina.
TECNICA 114
1
11
4
12
5
14 6 8 16 23
1310 15
3
19
9
21
17
18
22
27
20
- 18 -
TECNICA 114
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 repairjob. 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
ELENCO PEZZI DI RICAMBIOPIECES DETACHEESSPARE PARTS LISTERSATZTEILLISTE
PIEZAS DE REPUESTO
ELENCO PEZZI DI RICAMBIOPIECES DETACHEESSPARE PARTS LISTERSATZTEILLISTE
PIEZAS DE REPUESTO
ELENCO PEZZI DI RICAMBIOPIECES DETACHEESSPARE PARTS LISTERSATZTEILLISTE
PIEZAS DE REPUESTO
ELENCO PEZZI DI RICAMBIOPIECES DETACHEESSPARE PARTS LISTERSATZTEILLISTE
PIEZAS DE REPUESTO
REF. REF. REF. REF. REF.
PotenziometroPotentiometrePotentiometerPotentiometerPotenciometroDiodoDiodeDiodeDiodeDiodoRaddrizzatore MonofaseRedresseur MonophaseSingle-phase RectifierEinphasiger GleichrichterRectificador MonofasicoCondensatoreCondensateurCapacitorKondensatorCondensadorIgbtIgbtIgbtIgbtIgbtRele'RelaisRelaisRelaisRelaisDiodoDiodeDiodeDiodeDiodoResistenzaResistanceResistorWiderstandResistencia
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
Manopola PotenziometroPoignee Pour PotentiometreKnob For PotentiometerPotentiometergriffMTermostatoThermostatThermal SwitchThermostatTermostatoInterruttoreInterrupteurSwitchSchalterInterruptorCavo Alim.Cable Alim.Mains CableNetzkabelCable Alim.VentilatoreVentilateurFanVentilatorAventadorInduttanza FiltroInductance FilterFilter InductanceFilter DrosselInduccion FiltroInduttanzaInductanceInductanceDrosselInduccionTrasformatore PotenzaTransformateur PuissancePower TransformerLeistungstransformatorTransformador De Potencia
alja Por Resist.electr.variable
FrontalePartie FrontalFront PanelGeraetefrontFrontalRetroPartie ArriereBack PanelRueckseiteTraseraManigliaPoigneeHandleHandgriffManijaFondoChassisBottomBodenteilBasePresa DinsePrise DixDinse SocketDinse SteckdoseEnchufe DinseKit MantelloKit CapotCover LitDeckel KitKit Panel De CoberturaKit SchedaKit FicheKit BoardKit KarteKit Tarjeta
- 19 -
TECNICA 114
Official servicing centersRepairing sheet
Date:
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) ItalyTel. +39 - 0445 - 858811Fax +39 - 0445 - 858800 / 858801E-mail: [email protected] http://www.telwin.com