cod. 988238
TECHNOLOGY 150-170-200
inver ter
TROUBLESHOOTING
TROUBLESHOOTING
AND
AND REPAIR
REPAIR MANUAL
MANUAL
“trouble-free
repair !”
TECHNOLOGY 150-170-200
INVERTER REPAIR
LABORATORY
5
1
3
4
8
2
6
7
ESSENTIAL INSTRUMENTS
1 Oscillo scopio 20Mhz dual-trace
cod. 802401 (*)
2 Static load generator
3 Variac 0 - 300v 1kw
cod. 802110 (*)
cod. 802402 (*)
4 Power supply unit HV
5 Digital multimeter
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.
3
TECHNOLOGY 150-170-200
Guide to repair of the inverter
1) Cleaning the inverter
3) Power and signal cabling checks
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:
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)
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).
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
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.
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).
2) Visual inspection of the inverter
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
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) 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.
4
TECHNOLOGY 150-170-200
5) Electrical measurements with the
machine running
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.
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.
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.
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.
Output voltage: 20,2V
Output current: 5A
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.
1
1
2
0
3
0
4
0
5
0
Figure 1
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.
5
TECHNOLOGY 150-170-200
Output voltage: 23,2V
Output current: 80A
1
1
2
2
3
2
4
2
5
2
Output voltage: 27,2V
Output current: 180A
Figure 2
6
2
1
3
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.
2
3
3
3
4
3
5
2
Figure 5
6
2
Switch number
Switch position
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
Figure 6
Output voltage: 25,2V
Output current: 130A
1
3
2
3
3
2
4
2
5
2
Figure 3
6
2
1
3
Switch number
Switch position
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
1
3
2
3
3
3
4
3
5
2
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.
Figure 4
6
2
Switch number
Switch position
6
TECHNOLOGY 150-170-200
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.
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.
Illustrated references
Switching auxiliary
power supply unit
Board
clamping
screws
Signal
cablings
SMD module
Current
limitation
setting
JP1
Max current
setting
Power
cabling
Relays Pre-charge
Primary
Photocouplers
K1, K2
resistor
current
ISO4, ISO5
R34
measurement T1
Secondary
circuit diodes D1, D2
Secondary
circuit relays C2, R4
Thermostatic
capsule cables S2
Thermostatic
capsule S1
7
Shunt
Signal
abling
Secondary
circuit diodes D3, 4, 5
Snubb
Recirculation
er network R35 diodes
Snubber
network R39
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 Geräts, Diseño seccionado maquina.
20
21
7
24
10
22
25
8
13
3
16
17
19
12
4
14
5
11
15
8
9
26
1
6
23
2
TECHNOLOGY 150-170-200
REF.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
19
20
21
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
990061 990059 990059
22
112017 112017 112017
23
112342 112342 112342
24
112357 112357 112357
25
112377 112376 112376
26
112514 112514 112514
27
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
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
322450 322450 322450
650414 650414 650414
655846 655847 655848
712035 712035 712035
990054 990054 990054
112512 112512 112512
TECHNOLOGY 150-170-200
Schema elettrico, Schéma électrique, 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!
10
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
Rectifier bridge
Electrolitical capacitors
Component ref.
Substitution of primary circuit board: si
Troubles evinced during repair :
Relais
In-rush limiter resistance
IGBT
Snubber
Secondary diodes
Potentiometer
Others
11
no
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
ISO
9001
CERTIFIED QUALITY SYSTEM