cod.

988238

TECHNOLOGY 150-170-200

inver ter

TROUBLESHOOTING TROUBLESHOOTING AND REPAIR MANUAL AND REPAIR MANUAL

trouble-free

repair !

TECHNOLOGY 150-170-200

INVERTER REPAIR LABORATORY

5 1 3 4 2 6

ESSENTIAL INSTRUMENTS
1 Oscillo scopio 20Mhz dual-trace 2 Static load generator 3 Variac 0 - 300v 1kw 4 Power supply unit HV 5 Digital multimeter cod. 802401 (*) cod. 802110 (*) cod. 802402 (*)

USEFUL INSTRUMENTS
6 Unwelding station

MISCELLANEOUS
7 Flat-jaw pincers 8 Cutting nippers

(*) The instruments with codes can be supplied by Telwin. Sale price on request.HV Power Supply Unit
2

TECHNOLOGY 150-170-200
The HV power supply module
The HV power supply module, the function of which is to power the switching power supply unit for the auxiliary voltages, can be easily constructed using the following components.

Power supply module wiring diagram

Insulation transformer 220-220 50VA (*) Rectifier bridge 36MB 80 Electrolytic capacitor 470uF 400V Resistor 100 Kohm 2 W Resistor 10 ohm 5 W Fuse carrier 5 x 20 Delayed fuse 1.5 A Female red and black spade terminal Plastic box code 112357 code 112514

(*) The insulation transformer can be replaced with two transformers of the same power by connecting the secondary circuits as shown in the following diagram:

Power supply unit wiring diagram:

Dismantling the inverter

A) B) C) D) E) Ensure that the power supply cable is disconnected from the mains. Unscrew the 8 screws located at the four corners of the two black plastic shells. Slide out firstly the upper shell and then the lower shell. Unscrew the two screws located below the wording "Technology inverter" on the inverter side panel. Slide out the casing by gently pulling it upwards.
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TECHNOLOGY 150-170-200

Guide to repair of the inverter

1) Cleaning the inverter
Open the inverter casing and thoroughly clean with compressed air. Dirt is dangerous especially for the inverter power components subject to high voltage and in particular the components that galvanically separate the primary from the secondary circuit. It is therefore important to pay particular attention to the following parts:

3) Power and signal cabling checks

It is good practice to check that: The power cabling: A) Mains power supply cable spade terminal (CN4, CN5, CN7, CN7A) B) Spade terminal from CN9, CN11 to mains switch C) Spade terminal from switch to rectifier bridge (CN2, CN10) D) Fan spade terminal (CN1, CN8) E) Power transformer primary spade terminal (CN3, CN6) The signal cablings: A) Connection of current transformer (T1) to mother board (A, B) B) Connection between photocouplers ISO4, ISO5 and mother plate (near module SMD) C) Panduit connector (J1) near the SMD module and 1) Thermostatic capsule 2) Shunt 3) Negative Dinse socket are in good condition. To check this, hold the cable between your thumb and index finger (as close as possible to the spade terminal or connector) and pull gently outwards; the cable must obviously not slide out of the spade terminal or the panduit connector (this is an insulation displacement connection). Screw and nut tightening check Check that the following screws and nuts are correctly tightened (circled in the photos): Primary board: IGBT Q6, Q7, Q8, Q9 n.4 diode bridge D19, D22 n.2 Secondary board: secondary diodes D1, 2, 3, 4, 5 n.5 shunt n. 2 transformer reactance n.2 thermostatic capsule n.2 Dinse sockets n. 2

Primary board: A) Rheophores of the IGBTs (Q6, Q7, Q8, Q9). Dust can settle between the rheophores and the dissipator. B) Rheophores of the recirculation diodes (D21, D25). Rheophores of the diodes on the snubber networks (D17, 18, 23, 24). C) Photocouplers (ISO4, ISO5).

Secondary board: A) Secondary power diodes (D1-2-3-4-5) B) Thermostatic capsule C) Fan: check whether the dust has affected correct rotation of the blades; if so, dismantle it and clean with compressed air. If the defect persists you are advised to replace the fan.

2) Visual inspection of the inverter

Ensure that there are no mechanical distortions, dents, damaged connectors and check that there are no signs of burning or breakage on the components listed below: A) Power supply switch Probable cause: mechanical or electrical shock, e.g. rectifier bridge or IGBT in short circuit, operation with load applied. B) Varistor VR1 Probable cause: inverter connected to a line voltage much higher than 230V (380V). C) Relay K1, K2 Probable cause: see power supply switch. Caution! If the relay contacts are stuck or dirty, do not try to clean them: replace the relays. D) Electrolytic capacitors C33 - C37 Probable cause: 1) Mechanical shock 2) Inverter connected to a line voltage much higher than 230V. 3) Rheophore of one or more capacitors broken: the remaining capacitors will therefore overheat and deteriorate. In this case the upper part of the capacitor will cave in and the insulating sheath covering it will be damaged at several points. 4) Ageing: after approximately 10,000 working hours. E) Current potentiometer R43 Probable cause: mechanical shock. F) Secondary diodes D1-2-3-4-5 Probable cause: snubber network interrupted, thermal contact between diode and dissipator not working properly (e.g. clamping screw loose). External voltage connected to the inverter output, e.g. different welders working on the same piece. G) IGBT transistors Q6, Q7, Q8, Q9 H) Primary diodes D17, D18, D20, D21, D23, D24, D25 I) Inverter transformer and filter inductance
4

4) Electrical measurements with the machine switched off

With the electronic tester set to diode testing, check the following components: A) Rectifier bridges D19, D22 B) IGBT Q6, Q7, Q8, Q9 (check absence of short circuits between Collector and Gate) C) Secondary circuit diodes between anode and cathode With the electronic tester set to Ohm, check the following components: A) Resistor R34 220 Ohm 5W (pre-charge) B) Resistors R35, R39 20 Ohm 20W (primary snubber) C) Resistor R4 10 Ohm 5W (secondary snubber) D) Secondary thermostatic capsule continuity check on diode dissipator S1: remove a spade terminal from the capsule and measure the sensor resistor which should be 0 Ohm. E) Thermostatic capsule continuity test on reactance S2: remove the spade terminal located above the thermostatic capsule and measure the resistor between the two wires coming from the reactance: it should be 0 Ohm.

TECHNOLOGY 150-170-200
5) Electrical measurements with the machine running
A) Disconnect the jumper JP1 (located on the mother board near the relays). B) Connect the (+) of the power supply module to the track that transmits the signal to R12. C) Connect the (-) of the power supply module to the (-) of the bridge D22 (near the electrolytic capacitor C37). D) Switch on the HV power supply unit. D) Visually check for energisation of the pre-charge relays. E) Check the following power supplies: Negative of the tester connected to case U2 (UA 7812) Voltage of out pin 7812 (+) of C16 = + 12V Voltage of anode D13 = - 12V Voltage between pin 8 (+) and 7 (-) of Iso4 (photocoupler) = 28V Voltage between pin 8 (+) and 7 (-) of Iso5 (photocoupler) = 28V Voltage between the (+) and (-) Dinse sockets = + 11.2V Caution! If this last voltage is missing, the inverter will not be able to operate! If the fault is in the following components: A) Switching auxiliary power supply unit B) IGBT (Q6-Q9) blown or in short circuit C) Primary diodes (D21, D25, D18, D23) blown or in short circuit you are advised to replace the primary board. For other faults the board can be repaired. Instructions for replacement of the main board code 114185187-189: A) Remove the following spade terminals: CN4 - CN5 Mains power supply CN9 - CN11 Power supply switch CN8 - CN1 Fan CN7 - CN7A Earth cables CN2 - CN10 Rectifier bridge CN3 - CN5 Power transformer J1 panduit connector (near the SMD module) B) Remove the current regulation knob. Remove the 2 screws located on the upper part of the front panel. Loosen the 2 screws located on the lower part of the front panel. Remove the 6 screws located on the outside edge of the longest side of the board. Remove the 4 screws that secure the primary board dissipator to the plastic side panels. The primary board, complete with dissipator, can now be removed and replaced with an equivalent one proceeding in reverse order. Caution! Before fitting the new board, carefully check that it has not been damaged during transport. The boards supplied by us have been pre-tested and therefore if, after replacement, the waveforms and current and voltage measurements do not correspond to those specified in the manual, do not adjust the calibration trimmers in the board (see inverter testing paragraph); search for the fault on the remaining elements that make up the inverter. Replacing the secondary diodes D1-2-3-4-5-6 Remove the screws securing the diodes to the dissipator. Unweld the diode copper strip using a 100W welder. Remove any dirt or protrusions from the dissipator. Spread a very thin layer of silicone grease on the dissipator. Fix the new diodes on the dissipator and then weld them onto the printed circuit. Caution! Check that R4 and C2 are welded on the printed circuit.
5

6) Inverter testing
1) Follow the Measurements with the Machine Operating procedure to power the auxiliary switching. 2) Connect a voltage probe x 100 between drain (tip) and source (clamp) of Q8. 3) Connect a voltage probe x 10 to the T1 (clamp near snubber resistor R39). 4) Connect the (-) of the HV power supply unit to the (-) of D19 and the (+) to the pin of the jumper JP1 facing the front panel. Connect the machine to the power supply by means of the variac, set the potentiometer to minimum and the switch to TIG. 5) Switch the HV power supply unit on, switch the variac on and bring it gradually to 230V checking the voltage and current on the IGBTs. At rated voltage check that the voltage and current are as in fig. 1.

Output voltage: 85V @ 230Vac Figure 1 6) Check the inverter no-load voltage: 85V @ 230V ac (if the mains voltage does not have this value the following formula can be applied: Output voltage = Mains voltage x 0.37). 7) First switch off the variac and after a few seconds the HV power supply unit, connect the jumper JP1 and connect the machine to the line. Switch the machine back on. MEASUREMENTS WITH DUMMY LOAD 1) Connect the static load generator, position the switches according to the table, set the current to approximately 5A @ 20.2V and check that the waveforms are as in figure 1.

Output voltage: 20,2V Output current: 5A

Figure 1

1 1

2 0

3 0

4 0

5 0

6 0

Switch number Switch position

2) Position the switches according to the table and set the current to 80A @ 23.2V. Check that the waveforms are as in fig. 2.

TECHNOLOGY 150-170-200

Output voltage: 23,2V Output current: 80A

Figure 2

Output voltage: 27,2V Output current: 180A

Figure 5

1 1

2 2

3 2

4 2

5 2

6 2

Switch number Switch position

1 3

2 3

3 3

4 3

5 2

6 2

Switch number Switch position

3) Apply the rated load: Technology 150 130A @ 25.2V Technology 170 160A @ 26.4V Technology 200 180A @ 27.2V Check that the waveforms are as in fig. 3,4,5.

4) If the maximum output current differs from the rated values of 6A maximum, R42 can be adjusted. 5) Check that the waveforms on the secondary diodes are as in fig. 6.

Maximum load Output voltage: 25,2V Output current: 130A Figure 6 Figure 3

1 3

2 3

3 2

4 2

5 2

6 2

Switch number Switch position

1 3

2 3

3 3

4 3

5 3

6 3

Switch number Switch position

(clamp on the dissipator, one probe x 100 on the anode of each of the two groups of diodes), in particular check that the inverse voltage peak does not exceed 250V.

Hot Start Control Set the 80 A static load generator to 23.2V. Set the switch on the inverter front panel to the hard position. Press the static load generator button. The instrument should go to 110A and then return to the rated current. Set the switch to soft and repeat the above procedure.

Output voltage: 26,4V Output current: 160A

Figure 4

1 3

2 3

3 3

4 3

5 2

6 2

Switch number Switch position

Forced Arc Control Set the 80 A static load generator to 23.2V. Set the switch on the inverter front panel to the hard position ( ) and reduce the welding current until the voltage reaches 10V. The current should settle and then drop sharply (cut-in of short circuit protection - the alarm led comes on). Set the switch to soft ( ) a nd repeat the above procedure.

TECHNOLOGY 150-170-200
7) Final testing
Leave the inverter operating at maximum power until the thermostatic capsule cuts in. Perform a brief welding operation with 2.5 diameter electrode, current around 80A and switch set to HARD position, checking the behaviour of the hot start and the forced arc. Caution! The voltage and current measurements with dummy load must be taken with a mains voltage of at least 215 Volts. This measurement must be taken on the power supply switch with the inverter set to maximum power. Given the tolerances of the static load resistors, the voltage can vary by +/- 5% compared to the rated value.

Illustrated references
Switching auxiliary power supply unit SMD module Max current setting Power cabling Snubb Recirculation er network R35 diodes

Board clamping screws

Signal cablings

Current limitation setting

JP1

Relays Pre-charge Primary Photocouplers K1, K2 resistor current ISO4, ISO5 R34 measurement T1

Snubber network R39

Secondary circuit diodes D1, D2

Secondary circuit relays C2, R4

Shunt

Signal abling

Thermostatic capsule cables S2

Thermostatic capsule S1
7

Secondary circuit diodes D3, 4, 5

TECHNOLOGY 150-170-200
ELENCO PEZZI DI RICAMBIO LISTE PIECES DETACHEES TECHNOLOGY SPARE PARTS LIST TECHNOLOGY ERSATZTEILLISTE TECHNOLOGY PIEZAS DE REPUESTO

150 170 200

Esploso macchina, Dessin appareil, Machine drawing, Explosions Zeichnung des Gerts, Diseo seccionado maquina.

20

21

7 24 10

25

22

16

19

14

11

26

13

17

12

15

23

TECHNOLOGY 150-170-200
REF.
ELENCO PEZZI DI RICAMBIO PIECES DETACHEES SPARE PARTS LIST ERSATZTEILLISTE PIEZAS DE REPUESTO Kit Diodo Kit Diode Kit Diode Kit Diode Kit Diodo Potenziometro Potentiometre Potentiometer Potenziometer Potenciometro Rele' Relais Relais Relais Relais Raddrizzatore Monofase Monofasique Redresseur Single-phase Rectifier Einphase Gleichrichter Rectificador Monofasico Diodo II Diode II Diode II Diode II Diodo II Condensatore Condensateur Capacitor Kondensator Capacitor Manopola Poignee Knob Griff Manija Kit Scheda Primario Kit Fiche Primaire Kit Primary Pcb Kit Primaertrafokarte Kit Tarjeta Primario Kit Scheda Secondario Kit Fiche Secondaire Kit Secondary Pcb Kit Sekundaertrafokarte Kit Tarjeta Secundario Deviatore Gareur Switch Schalter Interruptor Interruttore Interrupteur Switch Schalter Interruptor Termostato Thermostat Thermal Switch Thermostat Termostato Assieme Condensatore Condensateur Capacitor Assembly Kondensatorsatz Grupo Capacitor Cavo Alimentazione Cable De Reseau Mains Cable Netzkabel Cable De Alimentacion Ventilatore Ventilateur Fan Ventilator Ventilador Trasformatore Di Corrente Transformateur De Courant Current Transformer Stromwandler Transformador De Corriente Trasformatore Di Potenza Poissance Transformateur Power Transformer Leistungstransformator Transformador De Potencia Pressacavo Presse Cable Cable Bushing Kabelhalter Prensa Cable Fibbia Per Cinghia Boucle Pour Courroie Belt Buckle Gurtschnalle Hebilla Para Correa Cinghia Courroie Belt Gurt Correa
TECHNOLOGY 145 TECHNOLOGY 165 TECHNOLOGY 200

REF. CODE CODICE KODE

ELENCO PEZZI DI RICAMBIO PIECES DETACHEES SPARE PARTS LIST ERSATZTEILLISTE PIEZAS DE REPUESTO Cornice Cadre Frame Rahmen Marco Fondalino Chassis Bottom Bodenteil Base Mantello Capot Top Cover Gehausedeckel Tapa Presa Dinse Prise Dix Dinse Socket Dinse Steckdose Enchufe Dinse Kit Igbt + Diodo Kit Igbt + Diode Kit Igbt + Diode Kit Igbt + Diode Kit Igbt + Diodo Resistenza Resistance Resistor Wiederstand Resistencia

TECHNOLOGY 145

TECHNOLOGY 165

TECHNOLOGY 200

CODE CODICE KODE

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 19 20 21

990061 990059 990059 112017 112017 112017 112342 112342 112342 112357 112357 112357 112377 112376 112376 112514 112514 112514 112559 112559 112559 990052 990055 990058 990053 990056 990056 122047 122047 122047 122381 122381 122381 122508 122508 122508 123543 123543 123543 132155 132155 132158 152101 152101 152101 152231 152231 152231 164781 164781 164781 322112 322112 322112 322406 322406 322406 322408 322408 322408
9

22 23 24 25 26 27

322450 322450 322450 650414 650414 650414 655846 655847 655848 712035 712035 712035 990054 990054 990054 112512 112512 112512

TECHNOLOGY 150-170-200
Schema elettrico, Schma lectrique, Diagram, Schaltplan, Esquema de conexiones.

CONTROL BOARD

SECONDARY CIRCUIT BOARD PRIMARY CIRCUIT BOARD

NOTE:

TECHNICAL REPAIR CARD. In order to improve the service, each servicing centre is requested to fill in the technical card on the following page at the end of every repair job. Thank you in advance for your co-operation!
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TECHNOLOGY 150-170-200

Official servicing centers Repairing card

Date: Inverter model: Serial number: Company: Technician: In which place has the inverter been used domanda Building yard Workshop Others: Supply: Power supply From mains without extension From mains with extension m: Mechanichal stresses the machine has undergone to Description:

Dirty grade Dirty inside the machine Description:

Kind of failure Component ref.

Rectifier bridge Electrolitical capacitors Relais In-rush limiter resistance IGBT Snubber Secondary diodes Potentiometer Others

Substitution of primary circuit board: si Troubles evinced during repair :

no

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TELWIN S.p.A. - Via della Tecnica, 3 36030 VILLAVERLA (Vicenza) Italy Tel. +39 - 0445 - 858811 Fax +39 - 0445 - 858800 / 858801 E-mail: telwin@telwin.com http://www.telwin.com

9001
CERTIFIED QUALITY SYSTEM

ISO