telwin tehnologi bw 150 170 200 186

cod. 988588

inver ter

TECHNOLOGY 150-170-200-186CE GE/

CONTENTS PAGE

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

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

SPARE PARTS LIST...............................................20

REPAIR SHEET......................................................22

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

TROUBLESHOOTING

AND REPAIR MANUAL

TROUBLESHOOTING

AND REPAIR MANUAL

TROUBLESHOOTING

AND REPAIR MANUAL

“reparation no problem !”

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TECHNOLOGY 150-170-200-186CE/GE

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BLOCK DIAGRAM

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

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LTE

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- 3 -

ANALYSIS OF THE BLOCK DIAGRAMNOTE: Unless indicated otherwise, it should be assumed thatthe components are assembled on the welding machine.

Consisting of:C3, R5, L1, C8, C9 .Prevents noise from the machine from being transmitted alongthe main power line and vice versa.

Consisting of:Q1, Q2, Q3, Q4Converts 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:T1 .The C.T. is used to measure the current circulating in the powertransformer primary and transmit the information to block 14(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).

Block 1

Block 2

Block 5

Block 6

Block 7

Block 8

EMC Filter

Chopper

Current transformer

Power transformer

(primary board)

Consisting of:D3, D5 (primary board).Converts the alternating mains voltage to continuous pulsedvoltage No D3 present onTechnology 150).

Consisting of:K1, K2, R1 (primary board).Prevents the formation of high transient currents that coulddamage the main switch, the rectifier bridge and theelectrolytic capacitors. When the power source is switched onrelays K1 and K2 are de-energised, capacitors C2, C4, C5, C6,C7 are therefore charged via R1. When the capacitors arecharged the relay will be energised. ( No K2 present onTechnology 150).

Consisting of:C2, C4, C5, C6, C7 (primary board).Converts the pulsed voltage arriving from the rectifier bridgeto continuous voltage ( No C7 present on Technology150).

(primary board).

(primary board)

Consisting of:D1, D2, D3, D5(secondary board).- D1 and D2 convert the current circulating in the transformer

to a single direction, preventing saturation of the nucleus.:No D2 onTechnology 150).

Rectifier bridge

Pre-charge

Filter

Secondary diodes

(N.B.

N.B.

N.B.

(N.B.

Block 3

Block 4

- D3, D5 recirculate the inductance output current (block 9)during the time when the IGBT's are not conducting,bypassing the power transformer (block 7).

Consisting of:L1, R1.The inductance levels the output current from the secondaryboard diodes making it practically direct.The shunt detects thecurrent circulating in the secondary and sends a voltage signalto block 16 (adder), which will process it.

Inductance and Shunt

hybrid board.

block 14 (dutycycle maker).

Block 9

Block 10

Block 11

Block 12

Block 13

Block 14

Block 15

Block 16

Secondary EMC Filter

Flyback power supply

IGBT Driver

Primary current reader and limiter

Duty cycle maker

Adder

Alarm Block

Consisting of: CY1, CY2.Prevents noise from the power source from being transmittedthrough the welding cables and vice versa.

Consisting of:T2, U2 (primary board).Uses switching methods to transform and stabilise the voltageobtained from block 4 (filter) and supplies auxiliary voltage topower block 12 (driver) and the

Consisting of:U1A, U1D (primary board).Takes the signal from block 11 (flyback power supply) and,controlled by block 14 (duty cycle maker), makes the signalsuitable for piloting block 6 (chopper).

Consisting of: R15 (primary board).Reads the signal from block 6 (current transformer) and scalesit down so it can be processed and compared in

Consisting of:U2 (hybrid board).Processes the information from block 15 (adder) and block 13(primary current reader and limiter) and produces a squarewave with variable duty cycle limiting the primary current to amaximum pre-set value under all circumstances.

Consisting of:U1A, U1D (hybrid board).Gathers all the information from block 13 (primary currentreader and limiter), from block 16 (alarms) and from block 18(current potentiometer), and produces a signal with a suitablevoltage for processing by block 14 (duty cycle maker).

Consisting of:Q5, R11, R14, R17 (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 signalobtained from block 18 (current potentiometer).

TECHNOLOGY 150-170-200-186CE/GETECHNOLOGY 150-170-200-186CE/GE

- 4 -

Block 25

Block 23

Block 27

Block 28

Block 29

Block 30

Block 31

Overvoltage safeguard

Undervoltage safeguard

Fan

Short circuit detector

Hot Start

Arc Force

Short circuit delay

Consisting of:U3A, R62, R68 (primary board).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:U3B, R61, R67(primary board).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:V1.Powered directly 230V by block 11 (flyback transformer) andcools the power components.

Consisting of: U3B (hybrid board).If the welding voltage is below 10V this circuit causes block 30(arc force) to trigger.

Consisting of: Q2,Q3,C9 (hybrid board).At the start of MMA welding, Hot Start generates a temporaryovercurrent based on the current setting made by block 20(current potentiometer) in order to pre-heat the electrode andprepare the weld pool.

Consisting of: Q6, Q7, C14 (hybrid board).If the arc voltage falls below 10V, this block produces atemporary increase in the output current, so as to detach theelectrode from the piece after it has become stuck.

Consisting of: U3B (hybrid board).If the output shorting persists this block shuts down thepower source via block 16 (alarms).


Block 17

Block 18

Block 19

Block 20

Block 21

Block 22

Block 23

Block 24

Alarm LED

Current potentiometer

Welding mode function selector

Shunt Amplifier

Maximum current regulator

Secondary diode thermostat

Inductance thermostat

Galvanic separation

Consisting of:D9 (primary board).It is switched on by block 16 (alarms) in the event of:1) Triggering of thermostatic capsule on inductance.2) Triggering of thermostatic capsule on secondary diodes.3) Triggering due to undervoltage.4) Triggering due to overvoltage.5) Short circuit at output (electrode holder clamp and earth

cable connected to one another or electrode stuck to piecebeing welded).

Consisting of:R16 (primary board).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: SW1 (primary board)The switch is used to select the type of welding procedure:TIG-Lift, Hard or Soft.

Consisting of: U4 (hybrid board)Amplifies the signal arriving from block 10 (shuntinductance), making it suitable for block 21 (maximumcurrent regulator).

Consisting of:R13 (primary board)Used to regulate the maximum welding current that can besupplied by the power source.

Consisting of:ST1When the temperature of the secondary diode dissipator is toohigh the thermostat cuts in, sending an alarm signal to block 24(galvanic separation). It is reset automatically when this alarmcondition is no longer present.

Consisting of:ST2When the temperature of the inductance is too high thethermostat cuts in, sending an alarm signal to block 24(galvanic separation). It is reset automatically when this alarmcondition is no longer present.

Consisting of: ISO3 (primary board).The signals arriving from blocks 22 and 23 (transformerthermostat and inductance thermostat) are separatedgalvanically and sent to block 16 (alarms) for detection of apossible alarm event.


(12)DRIVER

IGBT (5)CHOPPER

(8)SECONDARY DIODES

(2)RECTIFIER

BRIDGE(5)CHOPPER (18)

CURRENTPOTENTIOMETER

(11)FLY-BACK

POWER SUPPLY

(4)FILTER

(1)EMC

FILTER

(9)SHUNT

(10)

FILTERSECONDARYEMC

(8)DIODESSECONDARY

(3)PRE-CHARGE

(17)ALARM

LED

HYBRID BOARD

(25-26)OVER/UNDER VOLAGE

SAFEGUARD

(22)

THERMOSTATSECONDARY DIODES

ILLUSTRATIONS

- 5 -

Primary board

Secondary board

(6)CURRENT

TRASFORMER

(24)GALVANIC

SEPARATION

(19)FUNCTIONSSELECTOR


General wiring diagram

- 6 -

WIRING DIAGRAMS


- 7 -

Schema elettrico scheda primario - Driver


Wiring diagram primary board - Power

- 8 -


Wiring diagram primary board - Power supply

Wiring diagram primary board - Driver

- 9 -

Wiring diagram secondary board


Wiring diagram hybrid board

4

3 81 2

95

7 6

- 10 -


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

REPAIR GUIDEREPAIR GUIDEREPAIR GUIDEREPAIR GUIDE

EQUIPMENT REQUIRED

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

8 Unsoldering station9 Miscellaneous tools

5 Differential probe 1/2006 Hall Probe cod. 802406

cod. 802403(*)(*)7 HV Power supply

WARNING:

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.

ANY CHECKS CARRIED OUT INSIDE THEMACHINEWHEN IT IS POWERED MAY CAUSESERIOUS ELECTRIC SHOCK DUETO DIRECTCONTACTWITH LIVE PARTS.

HV POWER SUPPLY MODULE

THE HV POWER SUPPLY is used to ensure operation of theswitching power supply (the circuit on the primary board supplyingauxiliary voltages), even when the machine is operating at lowvoltage.It is easy to build using the electrical diagrams in fig. A forreference and using the following components or, alternatively, itcan be ordered fromTelwin.

T1 = insulation transformer 230-230V 50VA(*)D1 = rectifier bridge 36MB 80 (cod.112357)C1 = electrolytic capacitor 470uF 400V ALL

(cod.112514)R1 = resistor 10 ohm 5W 5%R2 = resistor 100K ohm 2W 5%F1 = delayed action fuse 1.5 A Fuse holder 5X20mmFemale red and black fastonPlastic box.

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, take elementary antistaticprecautions (use antistatic footwear 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 mm above the board.

D) If silicone is removed from some points on the boards, it shouldbe re-applied. Use only non-conducting neutral or oximicreticulating silicones (e.g. DOW CORNING 7093). Otherwise,silicone that is placed in contact with points at differentpotential (rheophores of IGBT's, etc.) should be left toreticulate before the machine is tested.

E) When the semiconductor devices are soldered the maximumtemperature limits should be respected (normally 300 C for nomore than 10 seconds).

F) It is essential to take the greatest care at each disassemblyand assembly stage for the various 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 themin the reverse order when re-assembling (damaged partsshould never be omitted but should be replaced, referring tothe spare parts list given at the end of this manual).

H) The boards (repaired when necessary) and the wiring shouldnever be 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 not touchthe boards when the machine is live.

Every operation should be carried out in completesafety with the power supply cable disconnected from the mainsoutlet:- Undo the 8 screws fastening the 2 plastic covers (4 each) to the

front and back .- Undo the 8 screws fastening the top cover to the structure

.- Slide out the top cover by pulling gently outwards .After completing the repairs, proceed in the reverse order to re-assemble the cover and do not forget to insert the toothed washeron the ground screw.

Using suitably dried compressed air, carefully clean thecomponents of the power source since dirt is a danger to partssubject to high voltages and can damage the galvanic separationbetween the primary and secondary.To clean the electronic boards we advise decreasing the airpressure to prevent damage to the components.It is therefore important to take special care when cleaning thefollowing parts

Check whether dirt has been deposited on the front and back airvents or has damaged the correct rotation of the blades, if there isstill damage after cleaning replace the fan.

rheofores of IGBT's Q1, Q2, Q3, Q4;rheofores of recirculating diodes D4, D8;rheofores of snubber network diodes D1, D6;

GENERAL REPAIR INSTRUCTIONS

TROUBLESHOOTING AND REMEDIES

N.B.

WARNING!

WARNING!

(figure 1A)

(figure 1B)(figure 1B)

---

°

1.0 Disassembling the machine

2.0 Cleaning the inside of the machine

Fan fig.2B

Primary board (fig.3:)

( )

- 11 -

10 5

F1 R1

R2

D1

T1

FIGURE A


ELECTRICAL DIAGRAM FOR POWER SUPPLY (HV OUTPUT):

THE INSULATION TRANSFORMER CAN BE REPLACED WITHTWO TRANSFORMERS OF THE SAME POWER,CONNECTING THE SECONDARIES ACCORDING TO THEFOLLOWING DIAGRAM:

--

N.B.

-

fig.3

fig.3

WARNING!

fig.3

fig.3

fig.3

WARNING!

WARNING!

fig.3

rheofores of opto-couplers ISO1 and ISO2;rheofores of connectors J4 and J6;

Do this if it is necessary to remove the primary board, otherwise itis possible to clean the part superficially from the side of thesecondary board.

If the primary and secondary boards are removed (with thediaphragm), carefully clean all the parts fastened to the base, orclean the base partially from the sides of the machine.

Make sure there is no mechanical deformation, dent, or damagedand/or disconnected connector.Make sure the power supply cable has not been damaged ordisconnected internally and that the fan works with the machineswitched on. Inspect the components and cables for signs ofburning or breaks that may endanger operation of the powersource.Check the following elements:

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

stuck together or dirty, do not attempt to separate them andclean them, just replace the relay.

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 damaged by 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:- excessive overheating related to faulty operation.

Probable cause:- mechanical shock.

Probable cause:- discontinuation in snubber network;- poorly functioning thermal contact between IGBT and

dissipator (e.g. loosened attachment screws:check);- faulty output connection.

Check it for colour changes.Probable cause:

overheating due to loosening of the screws connecting the shuntto the PCB.

Inspect the windings for colour changes.Probable causes:- aging 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 and thumb (asclose as possible to the fastons or connectors) and pull outwardsgently: the cables should not come away from the fastons orconnectors.N.B. If the power cables are not tight enough this couldcause dangerous overheating.

A) With the multimeter set on diode testing check the followingcomponents (joint voltages not less than 0.2V):- rectifier bridges D3, D5 ( );- IGBT's Q1, Q2, Q3, Q4, (no short circuits between collector-

gate and collector-emitter ( );

Before proceeding with faultfinding, we should remindyou that during these tests the power source is powered andtherefore the operator is exposed to the danger of electric shock.The tests described below can be used to check the operation ofthe power and control parts of the power source.

A) From the primary board, disconnect fastons CN3 (XF+) andCN10 (XF-) for the power transformer ( ).B) On the primary board disconnect the jumper on JP1.C) Connect the HV power supply OUT (code 802403) on theprimary board as follows ( ):- (+) Positive (clamp) to rheofore of resistor R35 towards JP1

(after removing jumper JP1);- (-) Negative (faston) to negative faston of diode bridge D3.D) Set up the oscilloscope with the voltage probe x100 connectedbetween the rheofore of R40B (collector Q10) towards JP1(probe) and the negative of diode bridge D3 (earth) to the primaryboard ( ).

the high frequency voltage will permanently damageany instrument connected to the generator. Before proceedingmake very sure that the fastons listed above are disconnected andcompletely isolated from one another.F) Connect the power supply cable to a single phase variac withvariable output 0-300Vac.

during testing prevent contact with the metal part ofthe torch because of the presence of high voltages that arehazardous to the operator.

A) Switch on the HV power supply (HV OUT) and make sure that( ):- pre-charge relays K1 and K2 close;- the fan starts to turn for the power transformer;

Power transformer and inductance assembly

Parts fastened to the base

Relays K1,K2 primary board fig.3

Electrolytic capacitors C2,C4,C6,C7 primary board (fig.3

IGBT's Q1, Q2, Q3, Q4 primary board (fig. 3)

Primary diodes D1,D4,D6,D8 primary board (fig.3)

Mode selector switches SW1 and SW3 primaryboard(fig.3)

Secondary diodes D1,D2,D3,D5 secondary board (fig.4)

Shunt R1 secondary board (fig.6)

Power transformer and filter inductance

3.0 Visual inspection of the machine

4.0 Checking the power and signal wiring

5.0 Electrical measurements with the machineswitched off

6.0 Electrical measurements with the machine inoperation

( )

)

.

6.1 Preparation for testing

6.2 Scheduled tests

Secondary board (fig.4):)-

--

fig. 4

fig.3fig.3

fig.4

fig.4

rheofores of secondary power diodes D1, D2, D3, D5 (N.B. notpresent onTechnology 150);thermostat ST1 on secondary diode dissipator;shunt R1.

- secondary diodes D1, D2, D3, D5 between anode andcathode ( ).The secondary diodes can be tested withoutremoving the primary board, placing a prod on the secondarydiode dissipator and the other in sequence on the 2 powertransformer output terminals.

B) With the multimeter in ohm mode check the followingcomponents:- resistor R1:47 ohm (precharge ).- resistors R2, R6:10 ohm (primary snubber ).- resistor R1:10 ohm (secondary snubber ).- thermostat continuity test on inductance and secondary

dissipator: disconnect connector J2 from the primary boardand make sure the resistance between pins 4 and 5 is approx.0ohm ( ).

E) Position the current potentiometer R16 on maximum (turnclockwise as far as it will go) and switch SW1 to SOFT (as far downas it will go);

Current potentiometer R16 (fig.3)Probable cause:- mechanical shock.

- 12 -


- yellow led alarm is turn off.Make sure the waveform shown on the oscilloscope

resembles .

if there is no signal it may be necessary to replace theintegrated circuit U2 or IGBT Q10 on the primary board ( ).C) Set up the multimeter in volt mode and make sure the primaryboard has the following voltages: ( ):- between the cathode of diode D32 (+) and the negative of diode

bridge D5 (-):equal to +15Vdc 3%;- between pin 3 (+) and the dissipator (-) of U4: equal to +12Vdc

5%;- between pin 3 (+) and pin 1 (-) of U6:equal to -12Vdc 5%;- between pin 8 (+) and pin 7 (-) of ISO1:equal to +26Vdc 5%;- between pin 8 (+) and pin 7 (-) of ISO2:equal to +26Vdc 5%;D) Switch off the HV power supply.E) Set up the oscilloscope with the voltage probe x10 connectedbetween the gate (probe) and the emitter (earth) of IGBT Q4 onthe primary board ).F) Switch on the HV power supply (HV out) and make sure thewaveform displayed on the oscilloscope resembles .

G) Repeat this test on Q1, Q2, Q3 as well.if the signal is not present there could be a fault in the IGBT

driver circuit, specifically ISO1 and ISO2 ( ), or in the hybridboard ( , in which case we recommend replacing the board).H) Switch off the HV and replace the 2 fastons connecting theprimary board and the power transformer (CN3 and CN10).I) Switch on the HV and the variac (initially set to 0V), close themain power supply switch on the machine and gradually increasethe voltage generated by the variac until it reaches 26Vac.J) Set up the oscilloscope with the voltage probe x100 connectedbetween the collector (probe) and the emitter (earth) of IGBT Q4on the primary board ( ).

K) Make sure the waveform shown on the oscilloscoperesembles

L) Repeat this test on Q2 as well, using the differential probe.If the signal is not present there may be a fault in the IGBT's

( ).M) Return the variac voltage to 0V, switch off the machine and theHV power supply.N) Disconnect the HV power supply, replace jumper JP1 on theboard.

P) Increase the voltage on the variac to 230Vac and make surethe alarm ceases (yellow LED D9 goes off).Q) Increase the voltage on the variac yet again to 275Vac 5%and make sure the machine registers an alarm again. Return thevariac voltage immediately to 230Vac and switch off the machine.

if an alarm persists (and is not caused by a fault in the hybridboard) there could be a fault in opto-isolator ISO3 or integratedcircuit U3 on the primary board ( ).

If repairing the board is complicated or impossible, it should becompletely replaced.The board is identified by a 6-digit code (printed in white on thecomponent side after the initialsTW).This is the reference code forrequesting a replacement: Telwin may supply boards that arecompatible but with different codes.

before inserting a new board check it carefully fordamage that may have occurred in transit. When we supply aboard it has already been tested and so if the fault is still presentafter it has been replaced correctly, check the other machinecomponents. Unless specifically required by the procedure, neveralter the board trimmers.

If the fault is in the primary board remove it from the machinestructure as follows:- with the machine disconnected from the main power supply

disconnect all the wiring from the primary board;- cut any bands restricting the board (e.g. on the power supply

cable and primary connections);- undo the screws fastening the front and back panels and

remove the panels from the machine structure;

- undo the screws fastening the primary board to the machinestructure ;

- remove the primary board by lifting it upwards.for assembly proceed in the reverse order.

B)Fig.B

N.B.fig.3

fig.3

(fig.3

fig.C

N.B.fig. 3

fig.3

fig.3

fig.D.

N.B.fig.5

N.B.

fig.3

WARNING!

(fig.2B)

N.B.

7.0 Repairs, replacing the boards

7.1 Removing the primary board (fig.3)

±

±±

±±

±

±

O) Switch the machine on again and gradually increase thevoltage generated by the variac to 115Vac 5% then make sure analarm is registered with yellow LED D9 lit up.

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

- 13 -


FIGURE B

SETTINGS:

· PROBE x100;

· 100 V/Div;

· 10 sec/Div.

· THE FREQUENCY

IS 35KHz ±15%;

· AMPLITUDE IS

450V ±10%;

µ

VERIFY THAT

SETTINGS:

· PROBE x10;

· 10V/Div;

· 10 sec/Div.

· POSITIVE AMPLITUDE

IS +18V ±10%;

· NEGATIVE AMPLITUDE

IS -10V ±10%.

µ

VERIFY THAT

FIGURE C

FIGURE D

SETTINGS:

· PROBE x100;

· 10V/Div;

· 10 sec/Div.

· AMPLITUDE ON

CH1 IS 35V ±20%;

µ

VERIFY THAT

Please read the procedure for replacing the IGBT'scarefully (fig. 3).

ohm

NOTE.

WARNING!

figure 3

WARNING!

The 4 IGBT's are attached to 2 different dissipators and whenevera replacement is required, both IGBT's should be replaced.- Unscrew the four (4) nuts that fix the dissipator onto the card;- unscrew the four (4) screws that fix the four (4) IGBT onto the

dissipator;- unscrew the two (2) screws that fix the two diode bridges onto

the dissipator;- remove the four (4) IGBT and the two (2) diode bridges by

unwelding the reophores, then remove tin from the p r i n t e dplates;

- remove dissipator from card.Before making the replacement make sure the componentspiloting the IGBT's are not also damaged:- with the multimeter set in mode make sure there is no

short circuit on the PCB between the 1 and 3 bump contacts(between gate and emitter) corresponding to eachcomponent;

- alternatively, resistors R3, R4, R7, R8 could have burst and/ordiodes D11, D12, D15, D16 may be unable to function at thecorrect Zener voltage (this should have shown up in thepreliminary tests);

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

- apply thermo-conductive grease following the generalinstructions.

- prepare the components for replacement. For the IGBT's,bend the rheofores at 90° (never bend and/or place the partsunder tension near the case).

- position the components on the dissipator with the fasteningscrews, but do not tighten the screws completely

- join the dissipator/component assembly to the printed board,inserting all the rheofores in the bump contacts and thethreaded spacers on the 4 attachment holes.

- attach the dissipators with the nuts and lock them once and forall in the following order:- the nuts fastening the dissipators to the printed circuit with a

torque wrench setting of 2 Nm ±20%;- the screws fastening the rectifiers to the dissipators with a

torque wrench setting of 2 Nm ±20%;- the screws fastening the IGBT's to the dissipators with a

torque wrench setting of 1 Nm ±20%.- solder the terminals taking care not to let the solder run along

them.- on the component side cut away the protruding part of the

rheofores and check they are not shorted (especially the gateand emitter).

The 4 IGBT's should belong to the same selection kitsupplied byTelwin.

- remove the 4 diodes by unsoldering the rheofores and alsoremove the solder from the bump contacts on the PCB;

- clean any irregularities or dirt from the dissipators. If the diodeshave burst the dissipator may be irreparably damaged: in such acase it should be replaced;

- apply thermoconductive paste following the generalinstructions;

- place the dissipator with the new components on the bumpcontacts of the PCB and fasten it down with the screws (torquewrench setting 1 Nm 20%);

- solder the terminals taking care not to let the solder run alongthem;

- on the soldering side cut the protruding part of the rheoforesand make sure they have not shorted (between cathode andanode).

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 ohmic loadcontactor.

Before proceeding to test the machine, we shouldremind you that during these tests the power source is poweredand therefore the operator is exposed to the danger of electricshock.The tests given below are used to verify power source operationunder load.

A) Connect the machine to the static load generator (code802110) using cables fitted with the appropriate dinse connectors.B) Set up the dual trace oscilloscope with the voltage probeCH1x100 connected between the collector (probe) and the emitterof Q4 (earth) on the primary board ( ).C) Pass the current probe of the Hall effect transducer along thecable connecting the power transformer at faston CN10 with thereference arrow pointing into CN10.D) Lastly, connect the Hall Probe and the current probe to theoscilloscope.E) Set up a multimeter in DC volt mode and connect the prods tothe OUT+ and OUT- dinse connections.F) On the front panel set switch SW1 to SOFT (as low as it willgo).

the high frequency voltage will permanently damageany instrument connected to the generator. Before proceedingmake very sure that the fastons listed above are disconnected andcompletely isolated from one another.

st rd

TESTING THE MACHINE

1.1 Preparation for testing7.2 Removing the hybrid board (fig.3)

7.3 Removing the secondary board (fig.4)

If the fault is in the hybrid board remove it from the primary boardas follows:

with the primary board removed from the machine structureunsolder the rheofores from the hybrid board on the solderingside;remove the solder from the bump contacts on the PCB;remove the hybrid board from the primary board;

for assembly proceed in the reverse order.

If the fault is in the hybrid board we strongly advise replacing itwithout further intervention.

If the fault is in the secondary board, unless the dissipator hasbeen damaged by a destructive explosion of the diodes, the boarddoes not generally need to be removed and the diodes can bereplaced directly with the board mounted on the machine. In anycase, it should be specified that to remove it, it is necessary to

separate the base from the machine structure as follows:- with the machine disconnected from the main supply undo the 4

side screws (2 on the front and 2 on the back) that attach theboard to the base;

- turn the machine upside down and undo the 2 screws fasteningthe base to the structure;

- finally remove the base from the structure.Complete removal of the secondary board from the structure:- undo the 4 side screws fastening the board to the machine

structure;- remove the 3 hexagonal-head screws that fasten the shunt and

connect the power transformer;- disconnect the wiring for the thermostatic capsule.

for assembly proceed in the reverse order.

The 4 secondary DIODES are attached to the dissipator andwhenever a replacement is made, all 4 diodes should be replaced:

make sure that resistor R1 and capacitor C1 of the snubberare soldered correctly ( ).

-

-

-

N.B.

N.B.

Take special note of the procedure for replacing thesecondary diodes:

N.B.fig.3

- 14 -


G) Connect the power supply cable to the 230Vac power supply.during testing prevent contact with the metal part of

the torch because of the presence of high voltages that arehazardous to the operator.

Switch on the machine, gradually increase the power supplyvoltage from 0V to 230Vac and make sure that:- the pre-charge relays on the primary board close;- the fan starts operating correctly;- the waveform displayed on the oscilloscope resembles

and the frequency is equal to +32.5KHz ±20%;

±±

WARNING!

A) Loadless test:

Fig. E

1.2 Scheduled tests

- the output voltage over dinse + and dinse is equal to 95Vdc10%.

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

- on the front panel position the current potentiometer onminimum (turn anti-clockwise as far as it will go);

- switch on the main switch;- start up on the ohmic load and make sure that:

- the waveforms displayed on the oscilloscope resemblethose in ;

- the output current is equal to +5Adc 20% and the outputvoltage is equal to +20.2Vdc %.

- switch off the ohmic load and switch off the main switch.

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

- on the front panel position the current potentiometer on approx.80A;

- start up the ohmic load and make sure that:- the waveforms displayed on the oscillscope resemble

those in ;- the output current is equal to +80Adc 10% and the output

voltage is equal to +23.2.Vdc 10%.- switch off the ohmic load and switch off the main switch.

- the ohmic load with the switch settings according to therelevantTechnology model (see tables in );

- on the front panel position the current potentiometer onmaximum (turn clockwise as far as it will go)

- start up on the ohmic load and make sure that:

- the waveforms displayed on the oscillscope resemble those in;

- the output current is equal to +130Adc ±3% and the outputvoltage is equal to +25.2Vdc ±5%; if the output current readingis not 130A ±3%, adjust the current using trimmer IMAX R13on the primary board ( ).

B) Rated load test:

fig.G

Fig.F

C) Intermediate load test:

fig.G

Fig.G

A) Rated load test:

Figs.H, I,J,K

Fig.H

fig.3

For the Technology 150

±

±±10

- 15 -


FIGURE E

SETTINGS

· THE FREQUENCY IS

60KHz ±5%;

· AMPLITUDE CH1 IS

340V ±10%;

:

· PROBE CH1 x100;

· 100 V/Div;

· PROBE CH4 =1A;

· 10mV/Div;

· 105 sec/Div.µ

VERIFY THAT

Number switch

Position switch

FIGURE E

6321 4 53 3 3 2 2 2

FIGURE H

SETTINGS

· THE FREQUENCY IS

32.5KHz ±20%;

· AMPLITUDE CH1 IS

340V ±10%;

· AMPLITUDE CH4 IS

56A ±10%;

:

· PROBE CH1 x100;

· 100 V/Div;

· PROBE CH4 =20A;

· 10mV/Div;

· 10 sec/Div.µ

VERIFY THAT

FIGURE EFIGURE F

6321 4 51 0 0 0 0 0

Number switch

Position switch

SETTINGS

· THE FREQUENCY IS

60KHz ±5%;

· AMPLITUDE CH1 IS

340V ±10%;

· AMPLITUDE CH4 IS 7A

±20%;

:

· PROBE CH1 x100;

· 100 V/Div;

· PROBE CH4 =5A;

· 10mV/Div;

· 10 sec/Div.µ

VERIFY THAT

Number switch

Position switch

FIGURE E

6321 4 52 2 2 2 1 0

FIGURE G

SETTINGS

· THE FREQUENCY IS

60KHz ±5%;

· AMPLITUDE CH1 IS

340V ±10%;

· AMPLITUDE CH4 IS

26A ±20%;

:

· PROBE CH1 x100;

· 100 V/Div;

· PROBE CH4 =20A;

· 10mV/Div;

· 10 sec/Div.µ

VERIFY THAT







Fig. I

fig.3

Fig.J

fig.3

For the Technology 186CE/GE- the waveforms displayed on the oscillscope resemble those in

;- the output current is equal to +145Adc ±3% and the output

voltage is equal to +25.8Vdc ±5%; if the output current readingis not 145A ±3%, adjust the current using trimmer IMAX R13on the primary board ( ).

- switch off the ohmic load and switch off the main switch.

- set up the dual trace oscilloscope, connecting probe CH1 x100 to the anode of diode D1 or D2 and probe CH2x100 to theanode of diode D3 or D5. Earth connections are both made tothe secondary dissipator;

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

- set up the ohmic load with the switch settings according to therelevantTechnology model (see tables at point 1.2D);

- on the front panel position the current potentiometer R7 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 thewaveforms displayed on the oscilloscope resemble those in

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

Set up the ohmic load as shown in the table in and thecurrent potentiometer on approx. 80A. Position switch SW1 onHARD (in the centre), start the ohmic load and make sure theoutput current reading shows approx. 110A ±10% then returns tothe current setting.

On the front panel set switch SW1 to SOFT (as low as it will go andthe welding current to maximum). Under the relevant load

Fig.K

fig.3

E) Checking the secondary diode voltages:

fig.L;

A)Arc Force testFig. G

B)Running time test and closing the machine

1.3 Operational tests

- 16 -

FIGURE E

6321 4 53 3 3 3 3 2

FIGURE J


Number switch

Position switch

FIGURE EFIGURE I

Number switch

Position switch6321 4 5

3 3 3 2 2 2

SETTINGS

· THE FREQUENCY IS

32.5KHz ±20%;

· AMPLITUDE CH1 IS

340V ±10%;

· AMPLITUDE CH4 IS

60A ±10%;

:

· PROBE CH1 x100;

· 100 V/Div;

· PROBE CH4 =20A;

· 10mV/Div;

· 10 sec/Div.µ

VERIFY THAT

FIGURE E

6321 4 53 3 3 2 2 2

FIGURE K

Number switch

Position switch

SETTINGS

· THE FREQUENCY IS

32.5KHz ±20%;

· AMPLITUDE CH1 IS

340V ±10%;

· AMPLITUDE CH4 IS

58A ±10%;

:

· PROBE CH1 x100;

· 100 V/Div;

· PROBE CH4 =20A;

· 10mV/Div;

· 10 sec/Div.µ

VERIFY THAT

SETTINGS

· THE FREQUENCY IS

32.5KHz ±20%;

· AMPLITUDE CH1 IS

340V ±10%;

· AMPLITUDE CH4 IS

60A ±10%;

:

· PROBE CH1 x100;

· 100 V/Div;

· PROBE CH4 =20A;

· 10mV/Div;

· 10 sec/Div.µ

VERIFY THAT

FIGURE EFIGURE L

SETTINGS

· REVERSE AMPLITUDE

ON CH1

250V.

· REVERSE AMPLITUDE

ON CH2

250V.

:

· PROBE CH1 x100;

· 50V/Div;

· PROBE CH2 x100;

· 50V/Div;

· 10 sec/Div.µ

VERIFY THAT

DOES NOT

EXCEED

DOES NOT

EXCEED

conditions for the particular Technology model (see tables at point1.2 D), switch on the machine and leave it running until thethermostatic capsules trigger (machine in alarm). After makingsure the internal wiring is positioned correctly assemble themachine once and for all.

with the machine set up according to the instructions in thehandbook make a test weld with an electrode diam. 2.5 and thecurrent setting at 80A.Monitor the dynamic behaviour of the powersource, also checking for the presence of the Arc Force SW1 onHARD (in the centre)

C)Welding testMMA:


FIG. 1A

FIG. 1B

ILLUSTRATIONS

TOCOVER SCREWS

TOPCOVER SCREWS

TOPCOVER SCREWS

- 17-

SCREWSFASTENINGBACK PANEL

SCRAWSFASTENINGBACK PANEL

SCREWSFASTENING

FRONT PANEL

SCREWSFASTENING

FRONT PANEL

- 18 -


FIG. 2A

FIG. 2B

POSITIVE DINSE

D9YELLOW LED

ALARM

BOTTOMCOVER SCREWS

NEGATIVE DINSE

SW1SWITCH

SELECTIONTIG/LIFT-HARD-SOFT

BOTTOMCOVER SCREWS

BOTTOMCOVER SCREWS

BOTTOMCOVER SCREWS

MAINS CABLE

GENERAL SWITCH

FAN

CURRENTPOTENTIOMETER

BOTTOMCOVER SCREWS

- 19 -


FIG. 4

FIG. 3

D4 D8 R6 Q4, Q3 D5, D3CN10 C7, C2, C4, C6 JP1 U2 R40B Q10

ISO2, ISO1 Q2, Q1 R2 R1 K2, K1 R13 D32 D9U4 U6

D1, D2 SHUNT R1R1, C1

D3, D5 THERMOSTATCABLE

ST1

SW1 R16

CN3 HYBRID BOARD

- 20 -


ELENCO PEZZI DI RICAMBIO - LISTE PIECES DETACHEES

SPARE 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.

Por pedir una pieza de repuesto sin referencia precisar: modelo-marca e tension de la maquina; numero di riferimento de lista; numero di matricula.

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

15

25

27

19

13

8

16

20

1 5 21 14

26 6 9 18

10 7 4 2 3 12 23 17

11 24 22

- 21 -


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

PotenziometroPotentiometrePotentiometerPotentiometerPotenciometroResistenzaResistanceResistorWiederstandResistenciaRele'RelaisRelaisRelaisRelaisRaddrizzatore MonofaseRedresseur MonophaseSingle-phase RectifierEinphasiger GleichrichterRectificador MonofasicoCondensatoreCondensateurCapacitorKondensatorCapacitorCondensatoreCondensateurCapacitorKondensatorCondensadorInterruttoreInterrupteurSwitchSchalterInterruptorDeviatoreGareurSwitchSchalterInterruptorTermostatoThermostatThermal SwitchThermostat

Cavo Alim.Cable Alim.Mains CableNetzkabeCable Alim.VentilatoreVentilateurFanVentilatorVentiladorTrasformatore Di Corrente TaTransformateur De Courant TaCurrent Transformer TaStromwandler TaTransformador De Corriente TaFibbiaBoucleBuckleSchnalleHebillaPressacavoPresse CableCable BushingKabelhalterPrensa CableCinghiaCourroieBeltGurtCorreaCorniceCadreFrameRahmenMarcoFrontalePartie FrontalFront PanelGeraetefrontFrontalRetroPartie ArriereBack PanelRueckseite

FondoChassisBottomBodenteilBasePresa DinsePrise DixDinse SocketDinse SteckdoseEnchufe DinseKit Diodi-igbt-resistenzaKit Diodes-igbt-resistanceKit Diodes-igbt-resistanceKit Diodes-igbt-wiederstandKit Diodos-igbt-resistenciaKit Scheda SecondarioKit Fiche SecondaireKit Secondary PcbKit SekundaertrafokarteKit Tarjeta SecundarioKit Scheda PrimarioKit Fiche PrimaireKit Primary PcbKit PrimärtrafokarteKit Tarjeta PrimarioKit DiodoKit DiodeKit DiodeKit DiodeKit DiodoKit ManopolaKit PoigneeKnob KitGriff KitKit ManijaKit Trasformatore + InduttanzaKit Tranformateur + ReactanceKit Transformer + ReactanceKit Trafo + ReaktanzKit Transformador + ReactanciaKit MantelloKit CapotKit CoverKit Deckel

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

26

27

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!

- 22 -


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 circuit board: yes no

Substitution of primary control board: yes no

Troubles evinced during repair :

TELWIN S.p.A.

800 801

- Via della Tecnica, 336030 VILLAVERLA (Vicenza) ItalyTel. +39 - 0445 - 858811Fax +39 - 0445 - 858 / 858E-mail: [email protected] http://www.telwin.com

telwin tehnologi bw 150 170 200 186

Documents

c7 primary board

block diagramnote

r1 primary board

wiring diagramsoperation

powertransformer primary

d5 primary board

repair guide

repair sheet