cod. 988656

TECNICA 140.1 - 142

inver ter

TECNICA 114

CONTENTS PAGE

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

REPAIR GUIDE...................................................... 9

SPARE PARTS LIST...............................................17

REPAIR SHEET......................................................19

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

Equipment required 9General repair instructions 10Troubleshooting and remedies 10Testing the machine 13Illustrations 15

TROUBLESHOOTING

AND REPAIR MANUAL

TROUBLESHOOTING

AND REPAIR MANUAL

TROUBLESHOOTING

AND REPAIR MANUAL

TROUBLESHOOTING

AND REPAIR MANUAL

“reparation no problem !”

TECNICA 114

- 2 -

BLOCK DIAGRAM

OPERATION AND WIRING DIAGRAMSOPERATION AND WIRING DIAGRAMSOPERATION AND WIRING DIAGRAMSOPERATION AND WIRING DIAGRAMS6CU

RR

EN

TTR

AN

SFO

RM

ER

1EM

CFI

LTER

7PO

WER

TR

AN

SFO

RM

ER

19

CU

RR

EN

TP

OTEN

TIO

METER

22

GA

LVA

NIC

SEP

AR

ATIO

N

11

ALIM

EN

TATO

RE

FLY-B

AC

K

12

AU

XIL

IAR

Y

PO

WER

SU

PP

LY

25

PO

WER

SU

PP

LYLED

26

FAN

15

DU

TY

CY

CLE

MA

KER

16AD

DER

17ALA

RM

BLO

CK

2PR

E-C

HA

RG

E

3REC

TIF

IER

BR

IDG

E

4FILT

ER

5CH

OP

PE

R

88SEC

ON

DA

RY

DIO

DE

9IND

UCT

ANCE

OU

TP

UT

14

PR

IMA

RY

CU

RR

EN

TR

EA

DER

AN

DLIM

ITER

13

DR

IVER

10SECO

ND

ARY

EMC

FILT

ERIN

PU

T

11

AU

XIL

IAR

YP

OW

ER

SU

PP

LYTR

IGG

ER

18

ALA

RM

LED

23

t

OV

ER

VO

LTA

GE

SA

FEG

UA

RD

21

IGB

TTH

ER

MO

STA

T

20

MA

XIM

UM

CU

RR

EN

TA

DJU

STM

EN

T

24

UN

DER

VO

LTA

GE

SA

FEG

UA

RD

- 3 -

ANALYSIS OF THE BLOCK DIAGRAMNOTE: Unless indicated otherwise, it should be assumedthat the components are assembled on the power board.

Consisting of:C1, C8, C9, L1.Prevents noise from the machine from being transmittedalong the main power line and vice versa.

Consisting of:K1, R2.Prevents the formation of high transitory currents that coulddamage the main power switch, the rectifier bridge and theelectrolytic capacitors.When the power source is switched on the relay K1 is de-energised, capacitors C2, C3, C4 are then charged by R2.When the capacitors are charged the relay is energised.

Consisting of:D1.Converts the mains alternating voltage into continuouspulsed voltage.

Consisting of:C2, C3, C4.Converts the pulsed voltage from the rectifier bridge intocontinuous voltage.

Consisting of:Q1.Converts the continuous voltage from the filter into a highfrequency square wave capable of piloting the powertransformer.Regulates the power according to the required weldingcurrent/voltage.

Consisting of:T2.The C.T. is used to measure the current circulating in thepower transformer primary and transmit the information toblock 17 (primary current reader and limiter).

Consisting of:T1.Adjusts the voltage and current to values required for thewelding procedure. Also forms galvanic separation of theprimary from the secondary (welding circuit from the powersupply line).

Consisting of:D22Diode D22 converts the current circulating in thetransformer to a single direction, preventing saturation ofthe nucleus, and recirculates the inductance output current(block 9) during the time when the IGBT's are notconducting, bypassing the power transformer (block 7).

Block 1

Block 2

Block 3

Block 4

Block 5

Block 6

Block 7

Block 8

EMC Filter

Pre-charge

Rectifier bridge

Filter

Chopper

Current transformer

Power transformer

Secondary diode

Block 9

Block 10

Block 11

Block 12

Block 13

Block 14

Block 15

Block 16

Block 17

Inductance

Secondary EMC Filter

Auxiliary power supply trigger

Auxiliary power supply

Driver

Primary current reader and limiter

Duty cycle maker

Adder

Alarm Block

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

Consisting of: C23, C24.Prevents noise from the power source from beingtransmitted through the welding cables and vice versa.

Consisting of:R13, R14, R15, C13Via the resistors, the power source supplies the necessaryvoltage to power block 12 (auxiliary power supply).

Consisting of:D10, C11, Q11, D11Rectifies, filters and stabilises the voltage arriving from thetertiary winding of the power transformer (block 7).

Consisting of:Q6, Q7, D46, D47Picks up the signal arriving from block 15 (duty cycle maker)adjusts it to suit piloting of block 5 (chopper).

Consisting of: D42, D45, R56, C44, R57, R58, R59.Reads the signal from block 6 (current transformer) andscales it down so it can be processed and compared inblocks 15 and 16.

Consisting of:U3, U2B.Processes the information from block 16 (adder) and block14 (primary current reader and limiter) and produces asquare wave with variable duty cycle limiting the primarycurrent to a maximum pre-set value under allcircumstances.

Consisting of:U1D.Gathers all the information from block 14 (primary currentreader and limiter), from block 17 (alarms) and from block19 (current potentiometer), and produces a signal with asuitable voltage for processing by block 15 (duty cyclemaker).

Consisting of:Q3, U1A, U1C.When an alarm is detected the power source output currentis drastically reduced by making direct adjustments to block15 (duty cycle maker) and directly changing the referencesignal obtained from block 19 (current potentiometer).

TECNICA 114

- 4 -

Block 26FanConsisting of:V1.Powered directly by block 12 (a ) andcools the power components.

uxiliary power supply

Block 18

Block 19

Block 20

Block 21

Block 22

Block 23

Block 24

Block 25

Alarm LED

Current potentiometer

Maximum current adjustment

IGBT Thermostat

Galvanic separation

Overvoltage safeguard

Undervoltage safeguard

Power supply LED

Consisting of:D35.It is switched on by block 17 (alarms) in the event of:1) Triggering of thermostatic capsule/thermostat on power

transformer.2) Triggering of thermostatic capsule on secondary diodes.3) Triggering due to overvoltage.4) Short circuit at output (electrode holder clamp and earth

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

Consisting of:R75.This is used to set the reference voltage needed to adjustthe output current: when the potentiometer knob is turnedthe cursor voltage varies, thus varying the current from theminimum to the maximum value.

Consisting of:R70, R71, R72, R73, R74.Used to adjust the maximum cutting current to be suppliedby the power source.

Consisting of:ST1When the temperature of the IGBT dissipator reaches agiven temperature the thermostat cuts in, sending an alarmsignal to block 22 (galvanic separation). It is resetautomatically when this alarm condition is no longerpresent.

Consisting of: ISO1The signal arriving from blocks 21 (IGBT thermostat) isseparated galvanically and sent to block 17 (alarms) fordetection of a possible alarm event.

Consisting of:R40, R41, R42, Q3.If the main supply voltage exceeds the maximum value thissafeguard triggers (a tolerance of approx. ±15% of thepower supply voltage is allowed: outside this range thesafeguard triggers).

Consisting of: R63, R64, U1C, Q8.If the main supply voltage falls below the minimumallowedvalue this safeguard triggers (a tolerance of approx.±15% of the power supply voltage is allowed: outside thisrange the safeguard triggers).

Consisting of:D34.Indicates when the power source is correctly powered andready for use.

TECNICA 114

- 5 -

Power boad

TECNICA 114

ILLUSTRATIONS

(13)DRIVER

(3)RECTIFIER

BRIDGE

(6)CURRENT

TRANSFORMER

(4)FILTER

(1)EMC FILTER

(5)CHOPPER

(7)POWER

TRANSFORMER

(10)SECONDARYEMC FILTER

(8)SECONDARY

DIODE

(2)PRE-CHARGE

(25)POWER

SUPPLY LED

(18)ALARM

LED

(9)INDUCTANCE

(12)AUXILIARY POWER

SUPPLY

(19)CURRENT

POTENTIOMETER

(16)

(17)ADDER

ALARM BLOCK

(15)DUTY CYCLE

MAKER

- 6 -

TECNICA 114

WIRING DIAGRAMS

General wiring diagram

PO

WER

PC

B

10

0/1

15

VO

R2

30

VO

NLY

MO

DELS

WIT

HPO

WER

SU

PPL Y

CH

AN

GE

+J4

+J4

-J4

-J4

J7J7

23

0V

23

0V

11

5V

11

5V

P4

P4

PE

L1N(L

2)

V1

Fan

V1

Fan

J1J1J2J2

OU

T+O

UT+

J3J3

OU

T-O

UT-

541

2

S1O

N/O

FF

541

2

S1O

N/O

FF

- 7 -

TECNICA 114

Wiring diagram power board – power supply

CN

1-9

CN

1-5

CN

1-2

CN

1-9

CN

1-3

CN

1-5

CN

1-8

CN

1-8

CN

1-4

CN

1-4

CN

1-6

CN

1-3

CN

1-2

CN

1-6

RIL

-I

CN

1-6

OU

TN

VA+

B-Q

8

E-Q

5

B-Q

5

CN

1-7

SO

V-T

CN

1-1

OU

TP DC

-

STS

_B

STS

_A

+12V

+12V

+5V

+12V

+5V

+12V

+5V

+12V

+12V

Te

rmo

sta

ti

R17

22

K0805

5%R

17

22

K0805

5%

R19

33

K1206

5%

R19

33

K1206

5%

Vcc

7

VF

B2

Ise

n3

GN

D5

OU

T6

CO

MP

1

VR

EF

8

RT

/CT

4

U1 U

C384

5A

D

U1 U

C384

5A

D

R58

120R

0805

5%R

58

120R

0805

5%

R5

33

K1206

5%

R5

33

K1206

5%

R14

33

K1206

5%

R14

33

K1206

5%

R1

33

K1206

5%

R1

33

K1206

5%

D24

10V

0W4

5%D

24

10V

0W4

5%

R13

4K

70805

5%R

13

4K

70805

5%D

28

BYG

20G

D28

BYG

20G

1 2

3D

38

BA

V99

D38

BA

V99

R15

100R

0805

5%

R15

100R

0805

5%

R26

14

K7

0805

1%R

26

14

K7

0805

1%

R6

100R

0805

5%R

6100R

0805

5%

D15

18V

0W4

5%D

15

18V

0W4

5%

R9

680R

0805

5%

R9

680R

0805

5%

C26

1u

25V

Z5U

C26

1u

25V

Z5U

R47

1K

0805

5%R47

1K

0805

5%

1

2 3

Q7

BC

807

Q7

BC

807

R32

10

K0805

5%

R32

10

K0805

5%

D29

18V

0W4

5%

D29

18V

0W4

5%

C11

1u

25V

Z5U

C11

1u

25V

Z5U

D37

4V

70W

42%

D37

4V

70W

42%

D19

BYG

20G

D19

BYG

20G

D16

18V

0W4

5%

D16

18V

0W4

5%

R16

1K

0805

5%

R16

1K

0805

5%

R59

470R

0805

5%R

59

470R

0805

5%

D25

BYG

20G

D25

BYG

20G

R48

47R

08

05

5%R

48

47R

08

05

5%

R42

1K

0805

5%R42

1K

0805

5%

R28

680R

0805

5%R

28

680R

0805

5%

R52

3K

31206

5%R

52

3K

31206

5%

R20

680R

0805

5%

R20

680R

0805

5%

D22

10V

0W4

5%D

22

10V

0W4

5%

D23

BYG

20G

D23

BYG

20G

1

23

Q2

BC

817

Q2

BC

817

R33

220

K0805

5%R

33

220

K0805

5%

R2

200R

1T

0W5

10%

R2

200R

1T

0W5

10%

R43

10

K0805

5%R

43

10

K0805

5%

D18

BYG

20G

D18

BYG

20G

12

3

D7

BA

V99

D7

BA

V99

C3

100p

50

VX

7R

C3

100p

50V

X7R

D27

BYG

20G

D27

BYG

20G

R50

2K

20805

5%R

50

2K

20805

5%R

22

2K

20805

5%

R22

2K

20805

5%

R61

10R

12

06

5%R

61

10R

12

06

5%

1

2 3

Q6

BC

807

Q6

BC

807

R3

100R

0805

5%R

3100R

0805

5%

1

23

Q1

BC

817

Q1

BC

817

D17

18V

0W4

5%

D17

18V

0W4

5%R

56

120R

0805

5%R

56

120R

0805

5%

12

13

14

4 11

U2D

LM324

U2D

LM324

R49

1K

1206

5%R49

1K

1206

5%

D26

BYG

20G

D26

BYG

20G

R38

2K

20805

5%R

38

2K

20805

5%

D30

18V

0W4

5%

D30

18V

0W4

5%

D4

24V

0W4

5%D

424V

0W4

5%

R44

4K

70805

5%R

44

4K

70805

5%

C14

100n

50V

X7R

C14

100n

50V

X7R

R30

4K

70805

5%R

30

4K

70805

5%

R24

33

K1206

5%

R24

33

K1206

5%

R27

10

K0805

5%R

27

10

K0805

5%R

11

4K

70805

5%R

11

4K

70805

5%

R57

6K

85W

5%R57

6K

85W

5%

Q4

IRFD

110

Q4

IRFD

110

12

3

D6

BA

V99

D6

BA

V99

C31

1u

25V

Z5U

C31

1u

25V

Z5U

R51

3K

31206

5%R

51

3K

31206

5%

R25

27R

1W5%

R25

27R

1W5%

12

3

D5

BA

V99

D5

BA

V99

R34

1K

0805

5%

R34

1K

0805

5%

R53

1K

0805

5%R53

1K

0805

5%

R10

470R

0805

5%R

10

470R

0805

5%

C13

100n

50V

X7R

C13

100n

50V

X7R

1

2 3

Q9

BC

807

Q9

BC

807

C2

100p

50V

X7R

C2

100p

50V

X7R

C10

100n

50V

X7R

C10

100n

50V

X7R

10 9

8

4 11

U2C

LM324

U2C

LM324

3 21

4 11

U2A

LM324

U2A

LM324

C23

100n

50V

X7R

C23

100n

50V

X7R

R7

10

K0805

5%R

710

K0805

5%

R36

2K

20805

5%R

36

2K

20805

5%

C29

100u

35V

All

C29

100u

35V

All

R21

14

K7

0805

1%R

21

14

K7

0805

1%

R55

470R

0805

5%R

55

470R

0805

5%

R31

100

K0805

5%

R31

100

K0805

5%

R29

22

K1206

5%R

29

22

K1206

5%

C19

100n

50V

X7R

C19

100n

50V

X7R

R54

10R

12

06

5%

R54

10R

12

06

5%

12

3

D1

BA

V99

D1

BA

V99

D20

BYG

20G

D20

BYG

20G

18

654 3

T1

TI1

20023

T1

TI1

20023

C24

1n

50V

NPO

C24

1n

50V

NPO

R62

1K

0805

5%R62

1K

0805

5%C

44u7

16V

TA

NC

44u7

16V

TA

N

C12

10n

50V

X7R

C12

10n

50V

X7R

214 3

ISO

1T

LP

621

ISO

1T

LP

621

D3

4V

70W

45%

D3

4V

70W

45%

5 67

4 11

U2

BLM

324

U2

BLM

324

C5

1n

50V

NPO

C5

1n

50V

NPO

12

3

D2

BA

V99

D2

BA

V99

1 2 3 4 5 6 7 8 9 10

11

12

Te

st P

oin

t

12

Fo

r iP

asso

2.5

4mm

Te

st P

oin

t

12

Fo

r iP

asso

2.5

4mm

R12

10

K0805

5%R

12

10

K0805

5%

C6

100n

50

VX

7R

C6

100n

50

VX

7R

1

23

Q3

BC

817

Q3

BC

817

R23

10

KL

in0W

220%

R23

10

KL

in0W

220%

C9

1n

50V

NPO

C9

1n

50V

NPOC

7100n

50V

X7R

C7

100n

50V

X7R

- 8 -

TECNICA 114

Wiring diagram power board – driver / control

4 2 51 3

6

- 9 -

TECNICA 114

REPAIR GUIDEREPAIR GUIDEREPAIR GUIDEREPAIR GUIDE

EQUIPMENT REQUIRED

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

ESSENTIAL INSTRUMENTS

USEFUL INSTRUMENTS

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

5 Unsoldering station6 Miscellaneous tools

WARNING:

WARNING:

WARNING:

BEFORE PROCEEDING WITH REPAIRS TO THEMACHINE READ THE INSTRUCTION MANUALCAREFULLY.

EXTRAORDINARY MAINTENANCE SHOULD BECARRIED OUT ONLY AND EXCLUSIVELY BYE X P E R T O R S K I L L E D E L E C T R I C A L -MECHANICAL PERSONNEL.

ANY CHECKS CARRIED OUT INSIDE THEMACHINE WHEN IT IS POWERED MAY CAUSESERIOUS ELECTRIC SHOCK DUE TO DIRECTCONTACTWITH LIVE PARTS.

GENERAL REPAIR INSTRUCTIONS

TROUBLESHOOTING AND REMEDIES

The following is a list of practical rules which must be strictlyadhered to if repairs are to be carried out correctly.A) When handling the active electronic components, the

IGBT's and Power DIODES in particular, takeelementary antistatic precautions (use antistaticfootwear or wrist straps, antistatic working surfacesetc.).

B) To ensure the heat flow between the electroniccomponents and the dissipator, place a thin layer ofthermo-conductive grease (e.g. COMPOUNDGREASIL MS12) between the contact zones.

C) The power resistors (should they require replacement)should always be soldered at least 3 mm above theboard.

D) If silicone is removed from some points on the boards, itshould be re-applied.

Use only non-conducting neutral or oximicreticulating silicones (e.g. DOW CORNING 7093).Otherwise, silicone that is placed in contact with pointsat different potential (rheophores of IGBT's, etc.) shouldbe left to reticulate before the machine is tested.

E) When the semiconductor devices are soldered themaximum temperature limits should be respected(normally 300 C for no more than 10 seconds).

F) It is essential to take the greatest care at eachdisassembly and assembly stage for the variousmachine parts.

G) Take care to keep the small parts and other pieces thatare dismantled from the machine so as to be able toposition them in the reverse order when re-assembling(damaged parts should never be omitted but should bereplaced, referring to the spare parts list given at theend of this manual).

H) The boards (repaired when necessary) and the wiringshould never be modified without prior authorisationfromTelwin.

I) For further information on machine specifications andoperation, refer to the Instruction Manual.

J) When the machine is in operation there aredangerously high voltages on its internal parts so do nottouch the boards when the machine is live.

Every operation should be carried out in complete safetywith the power supply cable disconnected from the mainsoutlet and should only by done by expert or skilledelectrical-mechanical personnel.- undo the 4 screws attaching the handle to the top cover

( );- undo the 2 screws fastening the two plastic shells to the

base:1 screw on each side (- undo the 2 screws attaching the handle to the base: 1

screw on each side ( );- on the top cover undo the nut for the earth connection

(J7);- slide out the top cover upwards ( );- undo the two screws fastening the power board to the

base.After completing the repairs, proceed in the reverse order tore-assemble the cover and do not forget to insert thetoothed washer on the ground screw.

Using suitably dried compressed air, carefully clean thecomponents of the power source since dirt is a danger toparts subject to high voltages and can damage the galvanicseparation between the primary and secondary. To cleanthe electronic boards we advise decreasing the air pressureto prevent damage to the components. It is thereforeimportant to take special care when cleaning the followingparts:

Check whether dirt has been deposited on the front andback air vents or has damaged the correct rotation of theblades, if there is still damage after cleaning replace the fan.

Make sure there is no mechanical deformation, dent, ordamaged and/or disconnected connector. Make sure thepower supply cable has not been damaged or disconnectedinternally and that the fan works with the machine switchedon. Inspect the components and cables for signs of burningor breaks that may endanger operation of the power source.Check the following elements:

Use the multimeter to check whether the contacts are stucktogether or open.Probable cause:- mechanical or electric shock (e.g. bridge rectifier or

IGBT in short circuit, handling under load).

Probable cause:- mechanical shock.

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

are stuck together or dirty, do not attempt to separatethem and clean them, just replace the relay.

N.B.

WARNING!

fig.1

fig.1);

fig.1

fig.1

N.B.

1.0 Disassembling the machine

2.0 Cleaning the inside of the machine

3.0 Visual inspection of the machine

Fan (fig.2A)

Power board figs.2A and 2B

Main power supply switch (fig.2A)

Current potentiometer R75 (fig.3)

Relay K1 (fig.3)

( ):

°

- rheofores of IGBT Q1;- rheofores of secondary power diode D22;- thermostat ST1 on the IGBT;- opto-coupler ISO1.

- 10 -

TECNICA 114

Electrolytic capacitors C2,C3 (fig.3)

IGBT's Q1 (fig. 4)

Secondary diodes D22 (fig.4)

Power transformer and filter reactance (fig. 2A)

6.1 Preparation for testing

6.2 Scheduled tests for theTECNICA 114 at low voltage

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

higher than the rated value;- broken rheophore on one or more capacitor: the

remainder will be overstressed and become damagedby overheating;

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

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

dissipator (e.g. loosened attachment screws:check);- excessive overheating related to faulty operation.

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

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

Inspect the windings for colour changes.Probable causes:- power source connected to a higher voltage than

280Vac;- ageing after a substantial number of working hours;- excessive overheating related to faulty operation.

It is important to check that all the connections are in goodcondition and the connectors are inserted and/or attachedcorrectly. To do this, take the cables between finger andthumb (as close as possible to the fastons or connectors)and pull outwards gently: the cables should not come awayfrom the fastons or connectors. If the power cables arenot tight enough this could cause dangerous overheating.In particular, on the power board it is necessary to makesure all the wiring is inserted correctly into thecorresponding connectors or fastons. Also make sure thatthe connections to the dinse sockets are attached correctlyto the power board.

A) With the multimeter set in mode checkthe following components (junction voltages not less than0.2V):- rectifier bridge D1 );- IGBT's Q1 (absence of short circuits between collector-

gate and between emitter-collector );- secondary board diodes D22 between anode and

cathode ( ).The secondary diodes can be checkedwithout removing the power board: with one prod on thesecondary board dissipator diodes and the other insequence on the two power transformer outlets;

B) With the multimeter set in ohm mode check the followingcomponents:- resistor R2:47ohm (pre-charge );- resistors R3, R4:22ohm (primary snubber );- resistor R22:10ohm (secondary snubber );- thermostat continuity test on IGBT dissipator: clean the

resin from the bump contacts for ST1(A,B) and measurethe resistance over these two bump contacts, it shouldbe approx 0 ohm ( ).

Before proceeding with troubleshooting, weshould remind you that during these tests the power sourceis powered and therefore the operator is exposed to thedanger of electric shock.The tests described below can beused to check operation of the power and control parts ofthe power source.

A) Set up a multimeter in DC volt mode and connect theprods to the OUT+ and OUT- bump contacts.B) Position the potentiometer R75 to maximum (clockwiseas far as it will go). to check correct operation of thecontrol circuit without powering the power board werecommend carrying out the test given at point 6.2,otherwise pass to the test at point 6.3.

A) Between the cathode of diode D10 (+) and the anode ofdiode D11(-) insert a stabilised power supply that is able tosupply 40Vdc 500mA.B) Set up the oscilloscope with the voltage probe x100connected between the gate of Q1 and the earth on theemitter, also of Q1 .C) Switch on the stabilised power supply (initially set to 0V)and gradually increase the generated voltage until itreaches 40Vdc.D) Make sure the waveform shown on the oscilloscoperesembles . if the signal is not present it may benecessary to replace component Q1 or, alternatively, thedriver circuit U3, Q6 and Q7 ( ).E) Set up a multimeter in volt mode and make sure that (

):- the voltage over pins 2 and 1 of J8 is equal to +23V ±5%;- the voltage over pins 5 and 1 of J8 is equal to +5Vdc

±5%;- the voltage over pins 4 and 1 of J8 is equal to +500mVdc

±5%;- the voltage over pins 8 and 1 of J8 is equal to 0Vdc.

4.0 Checking the power and signal wiring

5.0 Electrical measurements with the machineswitched off

6.0 Electrical measurements with the machine inoperation

N.B.

diode testing

(fig.3

fig.4

fig. 4

fig.3fig.3

fig.3

fig.2B

WARNING!

N.B.

(fig.3)

fig. A N.B.

fig.3fig.

3

(No C3 on 230V version ofTecnica 114):

- 11 -

TECNICA 114

FIGURE A

SETTINGS:

· PROBE CH1 x10;

· 5 V/Div;

· 10 sec/Div.

· :

60KHz ±10%.

· POSITIVE

AMPLITUDE IS

+16V ±10%;

· NEGATIVE

AMPLITUDE IS

-5V ±10%.

µ

VERIFY THAT:

THE FREQUENCY IS

6.3 Scheduled tests for theTECNICA 114 (230V)

6.4 Scheduled tests for theTECNICA 114 (115V)

7.1 Removing the power board (fig.2A)

A) Disconnect the stabilised power supply from the powerboard.B) Set up the dual trace oscilloscope. Connect probe CH2(x100) to the collector of Q1 and probe CH1 (x10) to thegate, also of Q1. The earth terminals are connectedtogether to the emitter of Q1.C) Connect the power supply cable to a single phasevariac with variable output 0-300Vac.D) Switch on the variac (initially set to 0V), close the mainpower supply switch on the power source and graduallyincrease the voltage generated by the variac until it reaches230Vac then make sure that:- the green power supply LED D34 lights up ( );- the fan starts to turn for the power transformer;- pre-charge relay K1 closes ( );- for voltages close to the rated power supply value

(230Vac ±15%) the power source does not signal analarm (yellow LED D35 off).

if the alarm persists in the power source this could bedue to a fault in the control components (in any caseproceed to make further tests).E) Make sure the waveform shown on the oscilloscoperesembles . if the signal is not present it may benecessary to replace component Q1 or, alternatively, thedriver circuit U3, Q6 and Q7 ( ).

F) Set up a multimeter in volt mode and make sure that ():

- the voltage over pins 2 and 1 of J8 is equal to +23Vdc±5%;

- the voltage over pins 5 and 1 of J8 is equal to +5Vdc±5%;

- the voltage over pins 4 and 1 of J8 is equal to +500mVdc±5%;

- the voltage over pins 8 and 1 of J8 is equal to 0Vdc;- the output voltage over OUT+ and OUT- is equal to

+80Vdc ±10%.G) Set up the dual trace oscilloscope. Connect the voltageprobe x100 between the gate of Q1 and the earth to theemitter, also of Q1 ( ). Probe CH2 (x10) to the rheoforeof R55 towards C11 and the earth to the anode of D11.H) Make sure the waveform shown on the oscilloscoperesembles .

I) Switch the power source off and on again and make surethat, after the transitory switch-on time, there is no alarm(yellow alarm LED D12 is off ) If an alarm persists(and is not caused by a fault in the control board) there couldbe a fault in the opto-coupler ISO1 ( ).

Power the power source at the rated voltage of115Vac. In this case the tests are exactly the same as thosefor the Tecnica 114 (230V) and can be carried out in thesame way.

If the fault is in the power board remove it from the bottom asfollows:- with the machine disconnected from the main supply,

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

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

power supply cable and connections to primary);- from the welding side undo the two screws fastening the

dinse sockets to the printed circuit board ( ).- undo the 2 screws fastening the board to the bottom (

).- undo the 2 screws fastening the board to the front and

back on the inside ( ).- after removing the screws, lift the board upwards to

remove it from the bottom of the machine.to re-assemble, proceed in the reverse order,

remembering to insert the toothed washers on the earthscrews.

fig.3

fig.3

N.B.

fig. B N.B.

fig.3

fig.3

fig. 3

fig.C

fig.3 . N.B.

fig.3

WARNING!

fig.1

fig.2Bfig.

2B

fig.2B

N.B.

7.0 Repairs, replacing the boardsIf repairing the board is complicated or impossible, it shouldbe completely replaced. The board is identified by a 6-digitcode (printed in white on the component side after theinitials TW). This is the reference code for requesting areplacement:Telwin may supply boards that are compatiblebut with different codes.

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

Warning:

- 12 -

TECNICA 114

FIGURE B

SETTINGS :

· PROBE CH1 x10;

· 10 V/Div;

· PROBE CH2 x100;

· 200 V/Div;

· 5 sec/Div.

TIME TOLLERANCES:

±20%.

· AMPLITUDE CH2

IS 320V ±10%;

· POSITIVE

AMPLITUDE CH1

IS +18V ±10%;

· NEGATIVE

AMPLITUDE CH1

IS -10V ±10%.

µ

VERIFY THAT

FIGURE C

SETTINGS:

· PROBE CH1 x100;

· 200V/Div;

· PROBE CH2 x10;

· 500mV/Div;

· 5 sec/Div.

TIME TOLLERANCES:

±20%.

· AMPLITUDE CH1 IS

640V ±10%;

· AMPLITUDE CH2 IS

500mV ±50%;

µ

VERIFY THAT

A) Take special note of the procedure for replacing theIGBT (fig. 4):

fig.2B

ohms

B) Take special note of the procedure for replacing thesecondary diodes (fig. 4):

N.B.fig.3

WARNING!

WARNING!

A) Minimum load test:

fig.D

fig.D

- to replace the IGBT undo the screws fastening thedissipator to the board ( );remove IGBT Q1 by unsoldering the rheofores and alsoremove the solder from the bump contacts on the PCB;

- remove the dissipator from the board;- undo the screws holding the IGBT.Before proceeding with the replacement make sure that theparts piloting the IGBT are not damaged as well:- with the multimeter set on check the PCB to make

sure there is no short circuit between the 1st and 3rdbump contacts (between gate and emitter)corresponding to each component;

- alternatively, resistors R8 and R9 could have blownand/or diodes D8 and D9 may be unable to work at acorrect Zener voltage (this should have been detected inthe preliminary tests);

- clean any irregularities or dirt from the dissipator. If theIGBT module has blown the dissipator may beirreparably damaged: in such a case it should bereplaced;

- apply thermoconductive paste following the generalinstructions;

- attach the new IGBT to the dissipator with the screw(torque wrench setting 1 Nm ±20%);

- place the dissipator with the new IGBT on the bumpcontacts of the PCB, interposing, and attach it with thescrews (torque wrench setting 1 Nm ±20%);

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

- on the solder side cut the protruding part of therheofores and make sure they have not shorted(between the gate and emitter in particular).

- undo the screws fastening the dissipator to the board;- remove the secondary diodes by unsoldering the

rheofores and also remove the solder from the bumpcontacts on the PCB;

- remove the dissipator from the board;- remove the springs locking the diode;- clean any irregularities or dirt from the dissipator. If the

diode has blown the dissipator may have beenirreparably damaged: in such a case it should bereplaced;

- apply thermoconductive paste following the generalinstructions;

- insert the new diode between the dissipator and thespring, taking care not to damage the component duringassembly (the spring should be inserted by pressure onthe dissipator in order to lock the component);

- place the dissipator with the new component on thebump contacts of the PCB, and attach it with the screws(torque wrench setting 1 Nm ±20%);

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

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

make sure that resistor R22 and capacitor C22 of thesnubber are soldered correctly to the PCB ( ).

Tests should be carried out on the assembled machinebefore closing it with the top cover. During tests with themachine in operation never commute the selectors oractivate the ohmic load contactor.

Before proceeding to test the machine, weshould remind you that during these tests the power sourceis powered and therefore the operator is exposed to thedanger of electric shock.The tests given below are used to verify power sourceoperation under load.

A) Connect the power source to the static load generator(code 802110) using cables fitted with the appropriate dinseconnectors.B) Set up the dual trace oscilloscope. Connect the voltageprobe x100 between the gate of Q1 and the earth to theemitter, also of Q1. Probe CH2 (x10) to the rheofore of R55towards C11 and the earth to the anode of D11.C) Set up a multimeter in DC volt mode and connect theprods to the OUT+ and OUT- bump contacts.D) Connect the power supply cable to the main 230Vacpower supply.

during testing prevent contact with the metalpart of the torch because of the presence of high voltagesthat are hazardous to the operator.

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

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

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

- the waveforms displayed on the oscilloscoperesemble those in ;

- the output current is equal to +9Adc ±5% and theoutput voltage is equal to +15Vdc ±5%;

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

-

1.1 Preparation for testing

1.2 Scheduled tests for theTECNICA 114 (230V)

TESTINGTHE MACHINE

- 13 -

TECNICA 114

SETTINGS:

· PROBE CH1 x 100

· 200V/Div;

· PROBE CH2 x10;

· 500mV/Div;

· 5 /Div.

TOLERANCES:

· FOR TIME 20%.

· PEAK AMPLITUDE

CH1 600V 10%.

· PEAK AMPLITUDE

CH2 900mV 30%.

µsec

±

±

VERIFY THAT:

FIGURE D

Posizione commutatore

Numero commutatore11

20

3 4 5 60 0 0 0

B) Intermediate load test:

fig.E

fig.E

C) Rated load test:

fig.F

fig.F

fig.5

D) Checking the secondary diode voltages:

fig.F

fig.H

E) Running time check and closing the machinefig. F

F) Welding test

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

- on the front panel turn the current potentiometer to 40A(approx.Half-way);

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

- the waveforms displayed on the oscilloscoperesemble those in ;

- the output current is equal to +40Adc ±10% and theoutput voltage is equal to +21.6Vdc ±10%;

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

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

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

- to the maximum (turn the knob clockwise as far as it willgo) and switch on the main switch;

- activate the static load generator and make sure that:- the voltage waveforms on the oscilloscope display

resemble those in ;- the output current is equal to 75Adc ±5% and the

output voltage is equal to +23.6Vdc ±5%; if theoutput current reading is not 75A ±5%, adjust thecurrent using jumpers JP1, JP2 and JP3 ( ).

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

- set up the dual trace oscilloscope by connecting probesCH1 and CH2 x100 to the two secondary outputs of thepower transformer. The earth terminals are connectedtogether to the secondary dissipator;

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

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

- switch on at the main switch;- on the front panel turn the current potentiometer to

maximum (turn clockwise as far as it will go);- start up the ohmic load and make sure the waveforms;- displayed on the oscilloscope resemble those in ;- switch off the ohmic load and switch off the main switch.

With the load status as in and the current adjustmentpotentiometer on maximum, switch on the power sourceand leave it in operation until the thermostatic capsulestrigger (machine in alarm status). Check the correctpositioning of the internal wiring and finally re-assemble themachine.

With the power source set up according to the instructionsin the handbook make a test weld at 40¸70A (electrodediameter 2.5 mm). Check the dynamic behaviour of thepower source.

1.3 Tests for theTECNICA 114 (115V)Power the power source at the rated voltage of

115Vac. In this case the tests are exactly the same as thosefor the TECNICA 114 (230V) and can be carried out in thesame way.

WARNING!

- 14 -

TECNICA 114

FIGURE F

12

22

32

42

52

61

SETTINGS:

· PROBE

· 200V/Div;

· PROBE CH2 x10;

· 1V/Div;

· 5 sec/Div.

TIME TOLLERANCES

±20%.

±

±2

CH1 x100

VERIFY THAT:

µ

· PEAK AMPLITUDE

CH1 680V 10%.

· PEAK AMPLITUDE

CH2 4.2V 0%.

Position of switch

Switch number

FIGURE G

SETTINGS:

· PROBE

· 50V/Div;

· PROBE CH2 x100;

· 5V/Div;

· 5 sec/Div.

TIME TOLLERANCES

±20%.

· REVERSE

AMPLITUDE CH1

AND CH2 DOES NOT

EXCEED

CH1 x100

250V.

VERIFY THAT

µ

FIGURE E

position switch

number switch11

21

31

41

51

61

SETTINGS:

· PROBE

· 200V/Div;

· PROBE CH2 x10;

· 1V/Div;

· 5 sec/Div.

TIME TOLLERANCES

±20%.

±

±

CH1 x100

VERIFY THAT:

µ

· PEAK AMPLITUDE

CH1 680V 10%.

· PEAK AMPLITUDE

CH2 2.5V 30%.

fig. 1

fig. 2A

- 15 -

TECNICA 114

SCREWS FASTENINGTOP COVER

POWER SUPPLY LED

CURRENT REGULATIONPOTENTIOMETER

ALARM LED

SCREWSFASTENING FRONT PANEL

SCREWS FASTENINGBACK PANEL

SCREWSFASTENING

HANDLE

DINSE SOCKET

ILLUSTRATIONS

POWERTRANSFORMER

SECONDARYDISSIPATORS

POWER SUPPLYINTERRUPTOR FAN WIRE

BOTTOM INDUCTANCEFAN

FILTERCAPACITORS

PRIMARYDISSIPATORS

DIODES BRIDGEDISSIPATOR

- 16 -

fig. 3

fig. 2B

DISSIPATORSFOR DIODES

DISSIPATORSFOR IGBT

THERMOSTATST1

TECNICA 114

BUMPCONTACTSTHERMOSTAT

ST1

RHEOFORESQ1

SCREWSFASTENING

DINSESOCKETS

IGBT DISSIPATORSCREWS FASTENING

Q1

SECONDARY DISSIPATORSCREWS

FASTENING

BUMP CONTACTSFAN

V1+,V1-

RHEOFORESD22

C2 U3Q1 D1 U2

R75

D34

ISO

R3, R4

D22

R55K1

D35

R2 Q11 J8 D11 U1

C22, R22

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

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

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

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

- 17 -

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

TECNICA 114

1

11

4

12

5

14 6 8 16 23

1310 15

3

19

9

21

17

18

22

27

20

- 18 -

TECNICA 114

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

ELENCO PEZZI DI RICAMBIOPIECES DETACHEESSPARE PARTS LISTERSATZTEILLISTE

PIEZAS DE REPUESTO

ELENCO PEZZI DI RICAMBIOPIECES DETACHEESSPARE PARTS LISTERSATZTEILLISTE

PIEZAS DE REPUESTO

ELENCO PEZZI DI RICAMBIOPIECES DETACHEESSPARE PARTS LISTERSATZTEILLISTE

PIEZAS DE REPUESTO

ELENCO PEZZI DI RICAMBIOPIECES DETACHEESSPARE PARTS LISTERSATZTEILLISTE

PIEZAS DE REPUESTO

ELENCO PEZZI DI RICAMBIOPIECES DETACHEESSPARE PARTS LISTERSATZTEILLISTE

PIEZAS DE REPUESTO

REF. REF. REF. REF. REF.

PotenziometroPotentiometrePotentiometerPotentiometerPotenciometroDiodoDiodeDiodeDiodeDiodoRaddrizzatore MonofaseRedresseur MonophaseSingle-phase RectifierEinphasiger GleichrichterRectificador MonofasicoCondensatoreCondensateurCapacitorKondensatorCondensadorIgbtIgbtIgbtIgbtIgbtRele'RelaisRelaisRelaisRelaisDiodoDiodeDiodeDiodeDiodoResistenzaResistanceResistorWiderstandResistencia

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

Manopola PotenziometroPoignee Pour PotentiometreKnob For PotentiometerPotentiometergriffMTermostatoThermostatThermal SwitchThermostatTermostatoInterruttoreInterrupteurSwitchSchalterInterruptorCavo Alim.Cable Alim.Mains CableNetzkabelCable Alim.VentilatoreVentilateurFanVentilatorAventadorInduttanza FiltroInductance FilterFilter InductanceFilter DrosselInduccion FiltroInduttanzaInductanceInductanceDrosselInduccionTrasformatore PotenzaTransformateur PuissancePower TransformerLeistungstransformatorTransformador De Potencia

alja Por Resist.electr.variable

FrontalePartie FrontalFront PanelGeraetefrontFrontalRetroPartie ArriereBack PanelRueckseiteTraseraManigliaPoigneeHandleHandgriffManijaFondoChassisBottomBodenteilBasePresa DinsePrise DixDinse SocketDinse SteckdoseEnchufe DinseKit MantelloKit CapotCover LitDeckel KitKit Panel De CoberturaKit SchedaKit FicheKit BoardKit KarteKit Tarjeta

- 19 -

TECNICA 114

Official servicing centersRepairing sheet

Date:

Inverter :

Serial number:

Company:

Technician:

model

In which place has the inverter been used?

Building yard

Workshop

Others:

Supply:

Power supply

From mains without extension

:From mains with extension m

Mechanichal stresses the machine has undergone to

cription:Des

Dirty grade

Dirty inside the machine

Description:

Rectifier bridge

Electrolytic capacitors

Relais

In-rush limiter resistance

IGBT

Snubber

Secondary diodes

Potentiometer

Others

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

Troubles evinced during repair :

TELWIN S.p.A. - Via della Tecnica, 336030 VILLAVERLA (Vicenza) ItalyTel. +39 - 0445 - 858811Fax +39 - 0445 - 858800 / 858801E-mail: telwin@telwin.com http://www.telwin.com