tecnica_150 152 170 168ge inverter sm

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CONTENTS PAGE

OPERATION AND WIRING DIAGRAMS................ 2

REPAIR GUIDE.......................................................10

SPARE PARTS LIST...............................................18

REPAIR SHEET......................................................20

Block diagram 2Analysis of the block diagram 3Illustrations 5Wiring diagrams 6

Equipment required 10General repair instructions 11Troubleshooting and remedies 11Testing the machine 14Illustrations 17

TROUBLESHOOTING

AND REPAIR MANUAL

TROU LESHOOTING

ND REP IR M NU L

TROUBLESHOOTING

AND REPAIR MANUAL

TROU LESHOOTING

ND REP IR M NU L

“ r e p a r a t i o n n o p r o b l e m ! ”

TECNICA140.1 - 142

inver ter

TECNICA150-152-170-168GE



TECNICA 150-152-170-168GE

- 2 -

BLOCK DIAGRAM

OPERATION AND WIRING DIAGRAMSPER TION N WIRING I GR MSOPERATION AND WIRING DIAGRAMSPER TION N WIRING I GR MS

2 2

2 3

2 5

1 1

1 7

1 9

2 0

1

2

3

4

5

7

8

9

1 0

1 4

1 5

1 6

1 8

1 2

D R I V E R

2 6

F A N

6

2 1

C O N T R

O L L

O

1 3

2 4

P O W E R S U P P L Y

I D E N T I F I C A T I O N

1 1 5 / 2 3 0 V

C H A N

G E

V O L T A

G E

( o n

l y

f o r

T e c n

i c a

1 5 2 )

+ |

O U T P U T

C U R R E N T

T R A N S F O R

M E R

I N D U C T A N C E

E M C F I L T E R I

I

°

P R I M A R Y

E M C F I L T E R

P O W E R

T R A N S F O R M E R

S E C O N D A R Y

D I O D E S

F I L T E R

C H O P P E R

R E C T I F I E R B R I D G E

P R E

- C H A R G E

I N P U T

P O W E R

S U P P L Y

L E D

F L Y

- B A C K

P O W E R

S U P P L Y

M A X I M U M

C U R R E N T

A D J

U S T

.

A L A R M L E D

P R I M A R Y

C U R

R E N T

R E A D E R A N D L

I M I T E R

U N D E R V O L T A G E

S A F E G U A R D

C U R R E N T

P O T E N T I O M E T E R

G A L V A N I C

S E P A R A T O R

A L A R M B L O C K

A D D E R

D U T Y

C Y C L E

M A K E R

O V E R V O L A T G E

S E F E G U A R D

P O W E R

T R A N S F O R M E R

T H E R M O S T A T



- 3 -

ANALYSIS OF THE BLOCK DIAGRAM

Block 1

Block 2

Block 3

Block 4

Block 5

Block 6

Block 7

Block 8

NOTE: Unless indicated otherwise, it should be assumed thatthe componentsare assembled on the power board.

Consisting of: C1, C2, C3,L1.Prevents noise fromthe machine from being transmitted alongthe main power line and vice versa.

Consisting of: K1, R1.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 C4, C5, C6, C7, C8 are then chargedby R1. When the capacitors are charged the relay isenergised.

Consisting of: D1.Converts the mains alternating voltage into continuous pulsedvoltage.

Consisting of: C4, C5, C6,C7.Converts the pulsed voltage from the rectifier bridge intocontinuous voltage .

Consisting of: Q1, Q2,Q3, Q4.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 14 (primarycurrent reader andlimiter).

Consisting of: T3.Adjusts the voltage and current to values required for thewelding procedure. Also forms galvanic separation of theprimary from the secondary (welding circuit from the powersupplyline).

Consisting of: D20, D21, D22, D23.D20, D21 converts the current circulating in the transformer toa single direction, preventingsaturation of the nucleus.D22, D23 recirculate the inductance output current (block 9)when the IGBT's are not conducting, bypassing the power

transformer (block 7).

EMCFilter

Pre-charge

Rectifier bridge

Filter

Chopper

Current transformer

Power transformer

Secondary diodes

(C7 fitted on Tecnica152 only)

Block 9

Block 10

Block 11

Block 12

Block 13

Block 14

Block 15

Block 16

Block 17

Inductance

Secondary EMC Filter

Flyback power supply

Driver

Primary current reader andlimiter

Duty cycle maker

Adder

Alarm Block

Alarm LED

Consisting of: L2.Levels the secondary board diodes’ output current making ipractically continuous.

Consisting of: C21, C22.Prevents noise from the power source from being transmittedthrough the welding cablesand vice versa.

Consisting of: T1, U2.Uses switching methods to transform and stabilise the voltageobtained from block 4 (filter) and supplies auxiliary voltage topower block 12 (driver) and the control board correctly.

Consisting of: ISO2, ISO3.Takes the signal from block 11 (flyback power supply) and

controlled by block 14 (duty cycle maker), makes the signasuitable for piloting block 6 (chopper).

Consisting of: R63, R64, R65 andpart of the control section.Reads the signal from block 6 (current transformer) and scalesit down so it can be processed and compared in blocks 14 and15.

Consisting of: U2 (control board).Processes the information from block 15 (adder) and block 13(primary current reader and limiter) and produces a square

wave with variable duty cycle limiting the primary current to amaximum pre-set value under all circumstances.

Consisting of: U1C(control board).Gathers all the information from block 13 (primary currenreader and limiter), from block 16 (alarms) and from block 18(current potentiometer), and produces a signal with a suitablevoltagefor processingby block 14 (duty cycle maker).

Consisting of: U1A, U1B(control board).When an alarm is detected the power source output current isdrastically reduced by making direct adjustments to block 14(duty cycle maker) and directly changing the reference signaobtained from block 18 (current potentiometer).

Consisting of: D14.It isswitchedon by block 16 (alarms) inthe event of:1) Triggering of thermostatic capsule/thermostat on powe

transformer.2) Triggering due to undervoltage.3) Triggering dueto overvoltage.4) Short circuit at output (electrode holder clamp and earth

cable connected to one another or electrode stuck to piece

being welded).

TECNICA 150-152-170-168GE



- 4 -

Block 26Fan Consisting of: V1.Powered directly by block 13 (power supply) and cools thepower components.

Block 18

Block 19

Block 20

Block 21

Block 22

Block 23

Block 24

Block 25

Current potentiometer

Maximum current adjustment

Power transformer thermostat

Galvanic separator

Overvoltage safeguard

Undervoltagesafeguard

Power supplyidentification 115/230V

Power supply LED

Consisting of: R52.This is used to set the reference voltage needed to adjust theoutput current: when the potentiometer knob is turned thecursor voltage varies, thus varying the current from theminimum to the maximum value.

Consisting of: R56, R57, R58.Used to adjust the maximum cutting current to be supplied bythe power source.

Consisting of: ST1.When the temperature of the power transformer is too high,the thermostat transmit the information to block 21 (galvanicseparation). It is reset automatically after the alarm conditionhas ceased.

Consisting of: ISO1.

Consisting of: R71, R73and part of the controlsection.If the main supply voltage exceeds the maximum value thissafeguard triggers (a tolerance of approx. ±15% of the powersupply voltage is allowed: outside this range the safeguardtriggers).

Consisting of: R72, R70and part of controlboard.If the main supply voltage falls below the minimum allowedvalue this safeguard triggers (a tolerance of approx. ±15% ofthe power supply voltage is allowed: outside this range thesafeguard triggers).

Consisting of: U1A, Q2,Q1 (voltagechange board).This is only present on machines with the automaticidentification function.Identifies the power supply voltage level (115V or 230V) and

compares the values with a reference signal. The comparisoncauses enabling of block 5 (filter) for operation in standardmode (230V) or as voltage duplicator (115V). This block alsoadjusts for the correct maximum current in relation to thedifferent operating modes.

Consisting of: D12 (D13 for Tecnica 152).Indicates when the power source is correctly powered andready for use.On machines operating exclusively at 230V it is green. Onmachines with automatic voltage identification (Tecnica 152) it

is green for operation at 230V and orange for operation at115V.

The signal arriving from blocks 20 and 21 (power transformerthermostat and secondary diodes) is separated galvanicallyand sent to block 16 (alarms) for detection of a possible alarmevent.

TECNICA 150-152-170-168GE



- 5 -

(12)DRIVER

(5)CHOPPER

(5)CHOPPER

(4)FILTER

(7)POWER

TRANSFORMER

TECNICA 150-152-170-168GE

(3)RECTIFIER

BRIDGE(11)

FLY-BACKPOWER SUPPLY CONTROL

BOARD

(1)PRIMARY EMC

FILTRE

(10)SECONDARYFILTER EMC

(8)SECONDARY

DIODES

(2)PRE-CHARGE

(18)CURRENT

POTENTIOMETER

(25)POWERSUPPLY

LED

(17)ALARM

LED

(9)INDUCTANCE

(6)

TRANSFORMERCURRENT

ILLUSTRATIONS

Power board



Wiring diagramgeneral - TECNICA 150 - 170 - 168GE

- 6 -

Wiring diagramgeneral TECNICA 152-

TECNICA 150-152-170-168GE

WIRING DIAGRAMS



Wiring diagram power board - power supply / control

- 7 -

TECNICA 150-152-170-168GE



- 8 -

TECNICA 150-152-170-168GE

Wiring diagram power board - power / driver



Wiring diagram - control board

Wiring diagram - change voltage board 115/230V (only for TECNICA)

TECNICA 150-152-170-168GE

- 9 -



4 2 51 3

6

- 10 -

TECNICA 150-152-170-168GE

REPAIR GUIDEEP IR GUI EREPAIR GUIDEEP IR GUI E

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:

BEFORE PROCEEDING WITH REPAIRS TOTHE MACHINE READ THE INSTRUCTIONMANUAL CAREFULLY.

EXTRAORDINARY MAINTENANCE SHOULDBE CARRIED OUT ONLY AND EXCLUSIVELYBY EXPERT OR SKILLED ELECTRICAL-MECHANICAL PERSONNEL.

WARNING:ANY CHECKS CARRIED OUT INSIDE THEMACHINE WHEN IT IS POWERED MAYCAUSE SERIOUS ELECTRIC SHOCK DUE TODIRECT CONTACT WITH LIVE PARTS.

GENERAL REPAIR INSTRUCTIONS

TROUBLESHOOTING AND REMEDIES

The following is a list of practical rules which must be strictlyadhered to if repairs areto be carried outcorrectly.A) When handling theactive electronic components, theIGBT's

and Power DIODES in particular, take elementary antistaticprecautions (use antistaticfootwear or wrist straps, antistaticworking surfaces etc.).

B) To ensure the heat flow between the electronic componentsand the dissipator, place a thin layer of thermo-conductivegrease (e.g. COMPOUND GREASIL MS12) between thecontact zones.

C) The power resistors (should they require replacement)

shouldalways be soldered at least 3 mmabovethe board.D) If silicone is removed from some points on the boards, it

should be re-applied.Use only non-conducting neutral or oximic reticulating

silicones (e.g. DOW CORNING 7093). Otherwise, siliconethat is placed in contact with points at different potential(rheophores of IGBT's, etc.) should be left to reticulatebeforethe machine is tested.

E) When the semiconductor devices are soldered themaximum temperature limits should be respected (normally300 C forno more than 10 seconds).

F) It is essential to take the greatest care at each disassemblyandassemblystagefor thevarious machine parts.

G) Take care to keep the small parts and other pieces that aredismantled from the machine so as to be able to position

them in the reverse order when re-assembling (damagedparts should never be omitted but should be replaced,referring to the spare parts list given at the end of thismanual).

H) Theboards (repairedwhen necessary) andthe wiringshouldneverbe modified without prior authorisation fromTelwin.

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 theboardswhenthe machine is live.

Every operation should be carried out in complete safetywith thepower supply cable disconnected from the mains outlet andshould only by done by expert or skilled electrical-mechanicapersonnel.

After completing the repairs, proceed in the reverse order to re-assemble thecover anddo notforget to insertthe toothed washeon theground screw.

Using suitably dried compressed air, carefully clean thecomponents of the power source since dirt is a danger to parts

subject to high voltages and candamage thegalvanicseparationbetween the primary and secondary.To clean the electronic boards we advise decreasing the aipressure to prevent damage to the components.It is therefore important to take special care when cleaning thefollowingparts

Check whether dirt has been deposited on the front and back aivents or hasdamaged thecorrect rotation of theblades, if there isstilldamage after cleaning replace thefan.

- rheofores ofIGBT's Q1, Q2, Q3, Q4;- rheoforesof recirculating diodesD40,D41;- rheofores ofsecondarypowerdiodesD21, D22,D 23;- thermostat ST1on power transformer;

- optocouplers ISO1;- control board.

N.B.

WARNING!

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. 2Aand 2B

( )

( ):

Make sure there is no mechanical deformation, dent, odamaged and/or disconnectedconnector.Make sure the power supply cable has not been damaged ordisconnected internally and that the fan works with themachine switched on. Inspect the components and cables fosigns of burning or breaks that may endanger operation of thepower source. Check the followingelements:

Use the multimeter to check whether the contacts are stucktogether or open. Probable cause:

- mechanical or electric shock (e.g. bridge rectifier or IGBTin short circuit, handling under load).

Probable cause:- mechanical shock.

Probable cause:- see main power supply switch. If the relay contacts

arestuck together or dirty, do not attempt to separate themand clean them, just replace the relay.

Probable cause :- mechanical shock;- machine connected to power supply voltage much highe

than the rated value;

Mainpower supply switch fig. 2A

Current potentiometer R52 fig.3

Relay K1 fig. 3

Electrolytic capacitors C4,C5, C6,C7 fig. 3

( )

( )

( )

( )

N.B.

°

- remove the current adjustment knob on the front panel of themachine ;

- undothe4 screwsattaching the handletothetopcover ( )-

(fig. 1)

fig. 1undo the 8 screws fastening the back and front plastic panels4 for the cap ( ).

- undo the 2 screws attaching the top cover to the base: 1 screwon each side ).

- undo the 2 screws fastening the top cover to the metastructure.

- slide out the top cover upwards

fig.1

(fig. 1

(C7fitted on Tecnica152 only)

- 11 -

TECNICA 150-152-170-168GE



- broken rheophore on one or more capacitor: theremainder will be overstressed and become damaged byoverheating;

- ageingafter a considerable number of working hours;- overheating caused by thermostatic capsule failure.

Probable cause:- discontinuationin snubber network;- fault indriver circuit;

- poorly functioning thermal contact between IGBT anddissipator (e.g. loosened attachment screws: check);

- excessiveoverheating related to faulty operation.

Probable cause:- excessiveoverheating related to faulty operation.

Probable cause:- discontinuationin 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 connectedto a higher voltage than 280Vac;- ageingafter a substantialnumber of working hours;- excessiveoverheating 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 thefastons or connectors) andpull outwards gently: the cables should not come away fromthe fastons or connectors. N.B. If the power cables are nottight enough this could cause dangerous overheating.

A) With the multimeter set in mode check thefollowingcomponents (junction voltages not less than0.2V):- rectifierb ridge D 1 ( );- IGBT'sQ1, Q2, Q3, Q4 (absence of short circuits between

collector-gate and between emitter-collector );- secondary board diodes D20, D21, D22, D23 between

anode and cathode ( ).Thesecondary diodescan bechecked without removing the power board: with one prodon the secondary board dissipator diodes and the other insequence on the two power transformeroutlets;

- viper U2 (absence of short circuits between pin 3 - pin 4and b etween p in 4 pin 2 , )

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

components:- resistorR1: 47ohm (pre-charge );- resistors R44,R45: 22ohm (primarysnubber );- resistorR20: 10ohm (secondarysnubber );- thermostat continuity test on the power transformer: clean

the resin from the bump contacts of ST1 (A,B) andmeasure the resistance between the two bump contacts, itshould b e a pprox.0 ohm( ).

Before proceeding with faultfinding, we shouldremind you that during these tests the power source ispowered and therefore the operator is exposed to the dangeof electric shock.Thetests described below can be used to check the operationof the power and control parts of the power source.

B) Set up the multimeter in DCmodeand connect the prods tothe OUT+ and OUT- bumpcontacts.C) Position the potentiometer R52 on maximum (turnclockwise as far as itwillgo).D) Connect the power supply cable to a single-phase variacwith variable output 0-300 Vac.

A) Switch on thevariac (initially set to the value 0 V), switch offthe main switch on the power source and increase the variacvoltagegradually to 230 Vac and make sure:- the green power supply LED D12 lightsup( ),- the fan for the power transformerstartsup correctly,- the pre-chargerelay K1commutes( ),- for voltages close to the rated power supply value (230Vac

±15%) the power source is not in alarm status (yellow LEDD14off).

if the power source stays in alarm status permanently,there could be a fault in the control board (in any case,proceed to make the other tests)B) Make sure the waveform shown on the oscilloscoperesembles .

if no signal is present, it may be necessaryto replace theintegrated circuit U2( ).C) With the multimeter set in mode make sure tha( ):-

D) Set up the dual trace oscilloscope. Connect the probe

CH1(x100) to the Q1 collector and probe CH2(x10) to the

IGBT's Q1, Q2, Q3, Q4 fig. 4

Primary diodesD40, D41 fig.4

Secondary diodes D20, D21, D22, D23 fig. 4

Power transformerand filter reactance (fig. 2A)

6.1 Preparation fortesting

6.2 Tests for the TECNICA 150 - 170 - 168GE

( )

( )

( )

4.0 Checking the power and signal wiring

5.0 Electrical measurements with the machine switched off

6.0 Electrical measurements with the machine inoperation

diode testing

fig. 3

fig. 4

fig. 4

fig.3 .

fig. 3fig.3

fig.3

fig. 2B

WARNING!

fig.3

fig.3

NB.

Fig. A

N.B.fig. 3

voltfig. 3

A) Set up the oscilloscope with the voltage probe x100connected between pin 3 of U2 and the earth on the anode odiode D2 ( ).

Set up a multimeter in volt mode and make sure that

- the voltage over the anode of D2(-) and the cathode of D2(+) isequal to +13V ±5%;

- the voltage over the anode of D30 (-) and the cathode oD7(+) is equal to +29V±5%;

- the voltage over the anode of D31 (-) and the cathode oD6(+) is equal to +29V±5%;

fig.3

(fig3):

- 12 -

FIGURE A

SETTINGS:PROBE CH1

AMPLITUD IS

- x100;- 100V/Div;

- 4 sec/Div.

VERIFICARE CHE:- FREQUENCY IS

65KHz ±10%;

-

450V ±10%.

µ

TECNICA 150-152-170-168GE



gate, also of Q1. The earth connections are both made to theemitterof Q1.E) Make sure the waveform displayed on the oscilloscoperesembles

F)

G)

H) Make sure the waveform displayed on the oscilloscoperesembles and that the output voltage over OUT+ andOUT- is equal to +80Vdc±10%.

I) Switch the power source on again and make sure that,following the brief start up time, the machine is not in alarmstatus (the yellow alarm LED D14 is off, ). If themachine remains in alarm status (and this is not due to a faultin the control board) there could be a fault in the photocouplerISO1 ( ).

In this case the tests are just the same and can be carried outwith either a 115Vor 230V power supply:- with a power supply of 115V±15% (LED D13 on and

orange) the voltage change board enables voltage

duplication by the input filter.- with a power supply of 230V±15% (LED D13 on and

green) the voltage change board disables voltageduplication by the input filter.

The intermediate band with a power supply between115V±15% and 230V±15% will be considered incompatiblesothe machine willshowalarm status (yellowLED D14 lit up)

If the fault is in the power board remove it from the bottom as

follows:- with the machine disconnected from the main supply

disconnect allthe wiringconnected to the board;- remove the current adjustment knob on the front panel o

the m achine ( );- remove any bands constraining the board (e.g. on the

power supply cable andconnections to primary);- undo the 3 screws fastening the board to the bottom (

);

The 4 IGBT's are attached to 2 different dissipators andwhenever a replacement is required, both IGBT's should beall replaced.- undo the screws attaching the dissipator to the board to

replace Q1, Q3 ( );- undo the screws attaching the dissipator to the board to

replace Q2, Q4 ( );- remove the 4 IGBT's and the 2 diodes D40, D41 by

unsoldering the rheofores and then clean the solder fromthe printed circuit bumpcontacts;

- remove the 2 dissipators from theboard;- undothe screws locking the 4 IGBT's.

Before making the replacement make sure the componentspiloting the IGBT's are not also damaged:- withthe multimeterset in modemakesurethere isno

short circuit on the PCB between the 1 and 3 bumpcontacts (between gate and emitter) corresponding toeach component;

- alternatively, resistors R40, R41, R42, R43 could haveburst and/or diodes D32, D33, D34 and D35 may beunable to function at the correct Zener voltage (this shouldhave shown up in the preliminary tests);

- clean any irregularity or dirt from the dissipators. If theIGBT's have burst the dissipators may have beenirreversibly damaged: in this case they should bereplaced;

- apply thermo-conductive grease following the genera

fig. B.

fig. C

fig. 3 N.B.

fig. 3

NOTE:

fig.1

fig2B

A) Please read the procedure for replacing the IGBT'scarefully:(fig. 4).

fig. 2B

fig. 2B

ohm

Set up the dual trace oscilloscope. Connect probe CH1(x100) to the collector of Q1 and probe CH2 (x10) to pin 9 on stripJ11. The earth terminals are connected together to the emitter ofQ1.

6.3 Tests for the TECNICA 161

7.1 Removing the power board fig. 2A( )

st rd

Repeat this test also for Q2, Q3.Q4 (for Q3 and Q4 use thedifferentialprobe).if the signal is not present there could be a fault in the

IGBT driver circuit ( ) or in the control board ( inthis case we recommendreplacing theboard).

N.B.fig. 3 fig. 2A,

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-digicode (printed in white on the component side after the initialsTW). This is the reference code for requesting a replacementTelwin may supply boards that are compatible but withdifferent codes.

before inserting a new board check it carefully fodamage that may have occurred in transit. When we supply aboard it has already been tested and so if the fault is stilpresent after it has been replaced correctly, check the othemachine components. Unless specifically required by theprocedure, never alter the board trimmers.

- remove the board from the metal structure, lifting iupwards.

for assembly proceed in the reverse order andremember to insert the toothed washer on the earth screw.

Warning:

N.B.

- 13 -

SETTINGS:

PROBE

PROBE

TIME TOLLERANCES

±20%.

:AMPLITUDE ON CH1

IS

AMPLITUDE ON

AMPLITUDE ON

- CH1 x100;- 100 V/Div;

- CH2 x10;- 10V/Div;- 5 sec/Div.

-

320V ±10%;

- POSITIVE

CH2IS +16V ±10%;

- NEGATIVE

CH2SIA -10V ±10%.

VERIFY THAT

µ

FIGURE B

SETTINGS:PROBE

PROBE

TIME TOLLERANCES

±20%.

AMPLITUDE ON

CH1ISAMPLITUDE ON CH2

IS

- CH1 x100

- 100V/Div;

- CH2 x10;

- 500mV/Div;- 5 sec/Div.

-

320V ±10%;-

500mV ±10%.

VERIFY THAT

µ

FIGURE C

TECNICA 150-152-170-168GE



instructions.- Insert the new IGBT's between thedissipator and the spring, taking care not to damage thecomponent during assembly (the spring should beinserted under pressure on the dissipator so as to lock thecomponent);

- place the dissipators with the new IGBT's and primarydiodes D40 and D41 ( Make sure there isinsulation between the case of diode D41 and thedissipator) in the PCB bump contacts, placing 4 spacers

between the dissipatorand the PCB(2 for each dissipator)and fasten them down with the screws (torque wrenchsetting for screws 1 Nm ±20%);

- solder the terminals taking care not to let the solder runalong them;

- on the welding side cut away the protruding part of therheofores and check they are not shorted (between thegate andemitter in particular).

The 4 SECONDARY DIODES are attached to the samedissipator, and when a replacement is required, all of themshouldbe replaced:

- undo the screws attaching the dissipator to the board, toreplace diodes D20, D21, D22and D23;

- remove the 4 secondary diodes unsoldering the rheoforesand cleaning any solder from the bump contacts on theboard;

- remove thedissipatorfromthe board;- remove thespring locking the4 diodes;- clean any irregularity or dirt from the dissipator. If the

diodes have burst the dissipator may have beenirreversiblydamaged: in this case it should be replaced;

- apply thermo-conductive grease following the generalinstructions;

- insert the new diodes between the dissipator and thespring, taking care not to damage the component during

assembly (the screw should be inserted under pressureon the dissipator so asto lock the component);

- place the dissipator with the new components in the PCBbump contacts and fasten them down with the screws(torque wrench setting for screws1 Nm ±20%);

- solder the terminals taking care not to let the solder runalong them;

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

make sure resistor (R20) and capacitor (C20) on thesnubber havebeen solderedto the PCB correctly ( ).

Whatever fault occurs in the control board, we stronglyrecommend its replacement without attempts at repair. Toremove it, cut and then unsolder from the power board theconnector keeping it fixed perpendicular to the PCB, replace itand re-solder the connector.

Tests should be carried out on the assembled machine beforeclosing it with the top cover. During tests with the machine inoperation never commute the selectors or activate the ohmicload contactor.

Before proceeding to test the machine, weshould remind you that during these tests the power source is

powered and therefore the operator is exposed to the dangeof electric shock.The tests given below are used to verify power sourceoperation under load.

.A) Connect the power source to the static load generatousing cables fitted with the appropriate dinse connectors(code 802110).

B)

C) Set up the multimeter in DC mode and connect the prodsto the OUT+ andOUT- bump contacts.D) Connect the power supply cable to the 230Vac powesupply.

During tests the operator must avoid contact withthe metal parts of the torch because of the presence odangerous, high voltage.

- activate the statico load generator and make surethat:- the waveforms displayed on the oscilloscope resemble

those in ;- the output current is +5Adc±20%, and the outpu

voltage is +20.2Vdc±20%.- deactivate the static load generator and switch off the

main switch.

- set up the ohmic load with the switch settings as in thetable in ;

- on the front panel turn the current potentiometer to 75A(approx. half-way);

- start uptheohmicload and makesure that:- the waveforms displayed on the oscilloscope resemble

those in ;- the output current is equal to +75Adc ±10% and the

output voltage is equal to +24Vdc±10%.- switchofftheohmicload.

WARNING!

B) Please read the procedure for replacing thesecondaryboard diodes carefully (fig. 4):

N.B.fig. 3

C) Please read the procedure for replacing the control

board (fig. 3):

WARNING!

WARNING!

A) Minimum

Fig. D

B) Intermediate load test:

fig.E

Fig. E

1.1 Preparation for testing

1.2 Testsfor the TECNICA150 - 170 - 168GE

Set up the dual trace oscilloscope, connecting probe CH1(x100) tothe collector onQ1 and probe CH2 (x10) topin 9 onstripJ11 (plasma control board). The earth terminals are connectedtogether to theemitter of Q1.

loadtest:

TESTING THE MACHINE

- set up the static load generator with the switch settings asin the table in ;

- on the front panel position the current potentiometer R23at (approx.) half way.

- switchon the mainswitch;

Fig. D

- 14 -

SETTINGS:

PROBE

PROBE

TIME TOLLERANCES

±20%.

:

AMPLITUDE ON CH1

IS

AMPLITUDE ON CH2IS

- CH1 x100- 100V/Div;

- CH2 x10;

- 500mV/Div;

- 5 sec/Div.

-

320V ±10%.

-1V ±10%.

VERIFY THAT

µ

FIGURE D

Position number

Switch number11

20

30

40

50

60

TECNICA 150-152-170-168GE



- set up the ohmic load with the switch settings as in the

table in ;- on the front panel turn the current potentiometer to

maximum (turn clockwise as far as itwillgo);- start uptheohmicload and makesure that:

- the waveforms displayed on the oscilloscoperesemble those i n ;

- the output current is equal to +130Adc ±5% and theoutput voltage is equal to +25.2Vdc ±5%; if the outputcurrent reading is not 130A ±5%, adjust the currentusing jumpersJP6,JP7 and JP8 ( ).

- switchofftheohmicload.


- on the front panel turn the current potentiometer tomaximum (turn clockwise as far as itwillgo);

- start uptheohmicload and makesure that:- the waveforms displayed on the oscilloscope

resemble those i n ;- the output current is equal to +150Adc ±5% and the

output voltage is equal to +26Vdc ±5%; if the output

current reading is not 150A ±5%, adjust the currentusing jumpers JP6,JP7 and JP8 ( ).

- switchoff the ohmic load.

- set up the dual trace oscilloscope, connecting probe CH1x 100 to the anode of diode D21 and probe CH2x100 to theanode of diode D22. Earth connections are both made tothe secondary dissipator;

- remove the multimeter from the OUT+ and OUT- bumpcontacts;

- set up the static load generator with the switch settings asinthe tablein

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

- activate the static load generator and make sure that the

waveforms displayed on the oscilloscope resemble thosein

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

With the load status as in and the currenadjustment potentiometer on maximum, switch on the powesource and leave it in operation until the thermostaticcapsules trigger (machine in alarm status). Check the correcpositioning of the internal wiring and finally re-assemble the

machine.

C) Rated load testfor TECNICA 150-186GE:

fig. F

fig.F

fig. 7

D) Rated load testfor TECNICA 170:

fig. G

fig.G

fig.7

E) Checking the secondary diode voltages:

fig.F, G orI;

fig.H;

F) Running time check and closing the machinefig. F or G

- 15 -

SETTINGS:

PROBE

PROBE

TIME TOLLERANCES

±20%.

AMPLITUDE ON CH1

ISAMPLITUDE CH2

IS

- CH1 x100- 100V/Div;

- CH2 x10;

- 2V/Div;- 5 sec/Div.

-

320V ±10%.-

5V ±10%.

VERIFY THAT

µ

FIGURE E

12

22

32

42

52

61

SETTINGS:

PROBE

PROBE

TIME TOLLERANCES

±20%.

:

AMPLITUDE ON

CH1 IS

AMPLITUDE ONCH2 IS

- CH1 x100- 100V/Div;

- CH2 x10;

- 5V/Div;

- 5 sec/Div.

-

320V ±10%;

-8V ±10%.

VERIFY THAT

µ

FIGURE F

Position switch

Number switch13

23

33

42

52

62

SETTINGS:

PROBE

TIME TOLLERANCES

±20%.

AMPLITUDE ON

CH1 IS

AMPLITUDE ONCH2 IS

- CH1 x100- 100V/Div;

- SONDA CH2 x10;

- 5V/Div;- 5 sec/Div.

-

320V ±10%;

-8V ±10%.

VERIFY THAT

µ

FIGURE G

13

23

33

43

52

61

SETTINGS:PROBE

PROBE

TIME TOLLERANCES

±20%.

:

- CH1 x100

- 50V/Div;

- CH2 x100;- 50V/Div;

- 5 sec/Div.

- REVERSE

AMPLIDUTE ON CH1AND CH2 DOES NOT

EXCEED 250V.

VERIFY THAT

µ

FIGURE H

TECNICA 150-152-170-168GE

Position number

Position number

Switch number

Switch number



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

1.3 Scheduled tests for the TECNICA 152 In this case it makes no difference whether the tests arecarried out with a 115V or a 230Vpower supply:

- with a 230V power supply (LED D13 on and green) thetests are exactly the same as those described for theTECNICA 150-168GE.

- with a 115V power supply (LED D13 on and orange) thetests are exactly the same as those described for theTECNICA 150-168GEwith the exception of the rated loadtest at point 1.2 C). To carry out the rated load test at 115Vsee point 1.3 A).


- on the front panel turn the current potentiometer tomaximum (turn clockwise as far as itwillgo);

- switchon atthemain switch;- start uptheohmicload and makesure that:- the waveforms displayed on the oscilloscope resemble

those in- theoutput current is equal to +100Adc ±5% and theoutput

voltage is equal to 24Vdc ±5%; if the output currentreading is not 100A±5%, adjust the current using jumpersJP6, JP7 and JP 8 ( ).

- switch off the ohmic loadand switchoff themain switch.

A) Rated load test:

fig. I

fig. I;

fig. 5

SETTINGS:

PROBE

PROBE

TIME TOLLERANCES

±20%.

:

AMPLITUDE ONCH1 IS

AMPLITUDE ON

CH2 IS

- CH1 x100

- 100V/Div;

- CH2 x10;- 5V/Div;

- 5 sec/Div.

-320V ±10%;

-

7V ±10%.

VERIFY THAT

µ

FIGURE I

Position switch

Number switch1

3

2

2

3

2

4

2

5

2

6

2

TECNICA 150-152-170-168GE

- 16 -



ILLUSTRATIONS

FIG. 1

NUTSFASTENING

METALLICSTRUCTURE

RHEOFORESQ1, Q4

FIG. 2A FIG. 2B

FIG. 4

IGBTQ1, Q3

D20, D22SECONDARY DIODES

D23

IGBTQ2, Q4

RHEOFORES

Q1, Q4

- 17 -

FIG. 3

R44

R45

R1

R52

U2D1 D6K1

ISO1

TECNICA 150-152-170-168GE

JUMPERJP6, JP7, JP8

NUTS FASTENINGMETALLIC STRUCTURE

D7 J11

D12

D14

DRIVER

D30, D31

R20, C20 D21

SCREWS FASTENINGTOP COVER

POWER SUPPLY LED

CURRENT REGULATIONPOTENTIOMETER

ALARM LED

SCREWSFASTENING FRONT PANEL

SCREWS FASTENINGBACK PANEL

SCREWS FASTENINGHANDLE

SCREWS FASTENINGHANDLE

DINSE SOCKET

POWERTRANSFORMER

SECONDARYDISSIPATORS

POWER SUPPLYINTERRUPTOR FAN WIRE

CONTROLBOARD

BOTTOM INDUCTANCE

FAN

FILTERCAPACITORS

PRIMARYDISSIPATORS

DIODES BRIDGEDISSIPATOR

BUMPCONTACTS

THERMOSTATST1

Q2, Q4

DISSIPATOR

SCREWS

FASTENING

SECONDARYDISSIPATOR

SCREWSFASTENING

BUMPCONTACTS

FANV1

NUTSFASTENING

METALLICSTRUCTURE

Q1, Q3

DISSIPATOR

SCREWS

FASTENING

DISSIPATORSFOR DIODES

DISSIPAT.FORIGBT

FLY BACKTRANSFORMER

THERMOSTATON POWER

TRANSFORMER

PRIMARYDIODE

D40

PRIMARYDIODE

D41



- 18 -

TECNICA 150-152-170-168GE

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 Ar tikel Nummer ist, benoetigen, bestimmen Sie bitte Folgendes: Modell-zeichen und Spannung des Geraetes; Teilliste Nuemmer;

Esploso macchina, Dessin appareil, Machine drawing, Explosions Zeichnung des Geräts, Diseño seccionado maquina.

20

19

23

1

10

21

18

12 11 14 9 2 4 6 25 15 16 5 7

24

22

13 17 3 8



- 19 -

TECNICA 150-152-170-168GE

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

PotenziometroPotentiometrePotentiometerPotentiometerPotenciometroResistenzaResistanceResistorWiederstandResistenciaDiodoDiodeDiodeDiodeDiodoRele'RelaisRelaisRelaisRelaisPwm ControllerPwm ControllerPwm ControllerPwm ControllerPwm ControllerCondensatoreCondensateurCapacitorKondensatorCondensador

Scheda ControlloPlatine De ControlControl PcbSteurungskarteTarjeta De ControloOpto-accoppiatoreOpto-accouplerOpto-couplerOpto-kopplerOpto-acopladorRaddrizzatoreRedresseurRectifierGleichrichterRectificador

Manopola PotenziometroPoignee Pour PotentiometreKnob For PotentiometerPotentiometergriffMalja Por Resist.electr.variableInterruttoreInterrupteurSwitchSchalterInterruptorCavo Alim.Cable Alim.Mains CableNetzkabelCable Alim.VentilatoreVentilateurFanVentilatorVentiladorInduttanza FiltroInductance FilterFilter InductanceFilter DrosselInduccion FiltroInduttanzaInductanceInductanceDrosselInduccion

TrasformatoreTransformateurTransformerTransformatorTransformadorTrasformatore PotenzaTransformateur PuissancePower TransformerLeistungstransformatorTransformador De PotenciaFrontalePartie FrontalFront PanelGeraetefrontFrontal

RetroPartie 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

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

TECHNICALREPAIR 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 repai

job. Please fill in this sheet as accurately as possible and send it to Telwin. Thank you in advance for your co-operation!



- 20 -

TECNICA 150-152-170-168GE

Official servicing centers Repairing 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) Italy

tecnica_150 152 170 168ge inverter sm

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