technology 150-170-200

cod. 988238

TECHNOLOGY 150-170-200

inver ter

TROUBLESHOOTING

AND REPAIR MANUAL

TROUBLESHOOTING

AND REPAIR MANUAL

“ t r o u b l e - f r e e r e p a i r ! ”

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INVERTER REPAIR

LABORATORY

ESSENTIAL INSTRUMENTS

Static load generator

Power supply unit HV

Digital multimeter

USEFUL INSTRUMENTSUnwelding station

MISCELLANEOUSFlat-jaw pincers

Cutting nippers

1 Oscillo scopio 20Mhz dual-trace cod. 802401 (*)

2 cod. 802110 (*)

3 Variac 0 - 300v 1kw cod. 802402 (*)

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

INVERTER REPAIR

LABORATORY

The HV power supply moduleThe 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 code 112357- Electrolytic capacitor 470uF 400V code 112514- 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

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

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1) Cleaning the inverterOpen 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:

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 capsuleC) 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 inverterEnsure 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 VR1Probable cause: inverter connected to a line voltage much higher than 230V (380V).

C) Relay K1, K2Probable 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 - C37Probable 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, Q9H) Primary diodes D17, D18, D20, D21, D23, D24, D25 I) Inverter transformer and filter inductance

3) Power and signal cabling checksIt 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 switchC) 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 capsule2) Shunt3) 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.4diode bridge D19, D22 n.2Secondary board:secondary diodes D1, 2, 3, 4, 5 n.5shunt n. 2transformer reactance n.2thermostatic capsule n.2Dinse sockets n. 2

4) Electrical measurements with the machine switched off

With the electronic tester set to diode testing, check the following components:A) Rectifier bridges D19, D22B) IGBT Q6, Q7, Q8, Q9 (check absence of short circuits between

Collector and Gate)C) Secondary circuit diodes between anode and cathodeWith 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.

Guide to repair of the inverter


5) Electrical measurements with the machine runningA) 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 = + 12VVoltage of anode D13 = - 12VVoltage between pin 8 (+) and 7 (-)of Iso4 (photocoupler) = 28VVoltage between pin 8 (+) and 7 (-)of Iso5 (photocoupler) = 28VVoltage between the (+) and (-) Dinse sockets = + 11.2VCaution! 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 unitB) IGBT (Q6-Q9) blown or in short circuitC) 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 114185-187-189:A) Remove the following spade terminals:

CN4 - CN5 Mains power supplyCN9 - CN11 Power supply switch CN8 - CN1 FanCN7 - CN7A Earth cablesCN2 - 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.

6) Inverter testing1) 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.

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 LOAD1) 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.

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.

Figure 1

Output voltage: 85V @ 230Vac

Figure 1

Output voltageOutput current

: 20,2V: 5A

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Switch number

Switch position

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3) Apply the rated load:Technology 150 130A @ 25.2VTechnology 170 160A @ 26.4VTechnology 200 180A @ 27.2VCheck 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.

(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 ControlSet 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.

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 ( ) and repeat the above procedure.

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6


: 23,2V80A:


: 25,2V: 130A


: 26,4V: 160A


: 27,2V: 180A

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Maximum load

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Switch number

Switch position

Switch number

Switch position

Switch number

Switch position

Switch number

Switch position

Switch number

Switch position


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.

Recirculation diodes

Snubber network R39

Photocouplers ISO4, ISO5

Primary current

measurement T1

Pre-charge resistor

R34

Signal cablings

Current limitation setting

JP1 Relays K1, K2

Board clamping screws

Snubber network R35

Power cabling

Max current setting

Switching auxiliary power supply unit

SMD module

Secondary circuit relays C2, R4

Shunt Signal abling

Secondary circuit diodes D1, D2

Thermostatic capsule S1

Secondary circuit diodes D3, 4, 5

Thermostatic capsule cables S2

Illustrated references

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ELENCO PEZZI DI RICAMBIOLISTE PIECES DETACHEESSPARE PARTS LISTERSATZTEILLISTEPIEZAS DE REPUESTO

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

TECHNOLOGY 150TECHNOLOGY 170TECHNOLOGY 200

20 21

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990059

112017

112342

112357

112376

112514

112559

990058

990056

122047

122381

122508

123543

132158

152101

152231

164781

322112

322406

322408

990059

112017

112342

112357

112376

112514

112559

990055

990056

122047

122381

122508

123543

132155

152101

152231

164781

322112

322406

322408

990061

112017

112342

112357

112377

112514

112559

990052

990053

122047

122381

122508

123543

132155

152101

152231

164781

322112

322406

322408

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Kit DiodoKit DiodeKit DiodeKit DiodeKit DiodoPotenziometroPotentiometrePotentiometerPotenziometerPotenciometroRele'RelaisRelaisRelaisRelaisRaddrizzatore MonofaseMonofasique RedresseurSingle-phase RectifierEinphase GleichrichterRectificador MonofasicoDiodo IIDiode IIDiode IIDiode IIDiodo IICondensatoreCondensateurCapacitorKondensatorCapacitorManopolaPoigneeKnobGriffManijaKit Scheda PrimarioKit Fiche PrimaireKit Primary PcbKit PrimaertrafokarteKit Tarjeta PrimarioKit Scheda SecondarioKit Fiche SecondaireKit Secondary PcbKit SekundaertrafokarteKit Tarjeta SecundarioDeviatoreGareurSwitchSchalterInterruptorInterruttoreInterrupteurSwitchSchalterInterruptorTermostatoThermostatThermal SwitchThermostatTermostatoAssieme CondensatoreCondensateurCapacitor AssemblyKondensatorsatzGrupo CapacitorCavo AlimentazioneCable De ReseauMains CableNetzkabelCable De AlimentacionVentilatoreVentilateurFanVentilatorVentiladorTrasformatore Di CorrenteTransformateur De Courant

Current TransformerStromwandlerTransformador De Corriente

Trasformatore Di PotenzaPoissance TransformateurPower TransformerLeistungstransformatorTransformador De Potencia

PressacavoPresse CableCable BushingKabelhalterPrensa CableFibbia Per CinghiaBoucle Pour CourroieBelt BuckleGurtschnalleHebilla Para CorreaCinghiaCourroieBeltGurtCorrea

CODE CODICE KODE CODE CODICE KODE

ELENCO PEZZI DI RICAMBIOPIECES DETACHEESSPARE PARTS LISTERSATZTEILLISTE

PIEZAS DE REPUESTO

ELENCO PEZZI DI RICAMBIOPIECES DETACHEESSPARE PARTS LISTERSATZTEILLISTE

PIEZAS DE REPUESTO

REF. REF.

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TECHNOLOGY145

TECHNOLOGY145

TECHNOLOGY165

TECHNOLOGY165

TECHNOLOGY200

TECHNOLOGY200

22

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CorniceCadreFrameRahmenMarcoFondalinoChassisBottomBodenteilBase

Presa DinsePrise DixDinse SocketDinse SteckdoseEnchufe DinseKit Igbt + DiodoKit Igbt + DiodeKit Igbt + DiodeKit Igbt + DiodeKit Igbt + Diodo

MantelloCapotTop CoverGehausedeckelTapa

ResistenzaResistanceResistorWiederstandResistencia

322450

650414

655846

712035

990054

112512

322450

650414

655847

712035

990054

112512

322450

650414

655848

712035

990054

112512


Schema elettrico, Schéma électrique, Diagram, Schaltplan, Esquema de conexiones.

NOTE:

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CONTROL BOARD

PRIMARY CIRCUIT BOARD

SECONDARY CIRCUIT BOARD

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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Official servicing centers

Repairing card Date:

Inverter :

Serial number:

Company:

Technician:

model

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

cription:Des

Dirty grade

Dirty inside the machine

Description:

Rectifier bridge

Electrolitical capacitors

Relais

In-rush limiter resistance

IGBT

Snubber

Secondary diodes

Potentiometer

Others

Kind of failure Component ref.Substitution of primary circuit board: si no

Troubles evinced during repair :


CERTIFIED QUALITY SYSTEM

ISO9001

TELWIN S.p.A. - Via della Tecnica, 336030 VILLAVERLA (Vicenza) Italy Tel. +39 - 0445 - 858811Fax +39 - 0445 - 858800 / 858801E-mail: [email protected] http://www.telwin.com

technology 150-170-200

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