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TECHNOLOGY 150-170-200-186CE/GE

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TROUBLESHOOTING AND REPAIR MANUAL
CONTENTS
PAGE 2 2 3 5 6

OPERATION AND WIRING DIAGRAMS................ Block diagram Analysis of the block diagram Illustrations Wiring diagrams

REPAIR GUIDE.......................................................10 Equipment required 10 General repair instructions 11 Troubleshooting and remedies 11 Testing the machine 14 Illustrations 17 SPARE PARTS LIST...............................................20 REPAIR SHEET...................................................... 22

"reparation

no

problem !"

INPUT
INDUCTANCE & SHUNT

PRIMARY EMC FILTER

RECTIFIER BRIDGE

PRE-CHARGE CHOPPER CURRENT TRANSFORMER POWER TRANSFORMER SECONDARY FILTER EMC SECONDARY DIAODES

FILTER

OUTPUT

BLOCK DIAGRAM

1 7

2 5 6 8 10

3

4

9

FAN
PRIMARY CURRENT READER AND LIMITER

OVERVOLTAGE SAFEGUARD

UNDERVOLTAGE SAFEGUARD

FLY-BACK POWER SUPPLY
IGBT DRIVER

V

V

MAXIMUN CURRENT REGULATOR

SHUNT AMPLIFIER

t

t

27

25
12

26

11

13

21

20

ALARM LED CURRENT POTENTIOMETER

ALARM BLOCK

DUTY CYCLE FORMATOR

ADDER

17 14 15

16

18

SECONDARY DIODES THERMOSTAT

INDUCTANCE THERMOSTAT

GALVANIC SEPARATION

SHORT CIRCUIT DELAY

ARC FORCE
i i

HOT START

WELDING MODE FUNCTION SELECTOR

TIG-LIFT
t t

HARD SOFT
19

22

23

24
30 29

31

SHORT CIRCUIT DETECTOR
V

OPERATION AND WIRING DIAGRAMS

TECHNOLOGY 150-170-200-186CE/GE

HYBRID

28

t

+
|

+

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TECHNOLOGY 150-170-200-186CE/GE TECHNOLOGY 150-170-200-186CE/GE
ANALYSIS OF THE BLOCK DIAGRAM
NOTE: Unless indicated otherwise, it should be assumed that the components are assembled on the welding machine. D3, D5 recirculate the inductance output current (block 9) during the time when the IGBT's are not conducting, bypassing the power transformer (block 7).

Block 9 Block 1
EMC Filter Consisting of: C3, R5, L1, C8, C9 (primary board). Prevents noise from the machine from being transmitted along the main power line and vice versa. Inductance and Shunt Consisting of: L1, R1. The inductance levels the output current from the secondary board diodes making it practically direct.The shunt detects the current circulating in the secondary and sends a voltage signal to block 16 (adder), which will process it.

Block 2
Rectifier bridge Consisting of: D3, D5 (primary board). Converts the alternating mains voltage to continuous pulsed voltage (N.B. No D3 present on Technology 150).

Block 10
Secondary EMC Filter Consisting of: CY1, CY2. Prevents noise from the power source from being transmitted through the welding cables and vice versa.

Block 3
Pre-charge Consisting of: K1, K2, R1 (primary board). Prevents the formation of high transient currents that could damage the main switch, the rectifier bridge and the electrolytic capacitors. When the power source is switched on relays K1 and K2 are de-energised, capacitors C2, C4, C5, C6, C7 are therefore charged via R1. When the capacitors are charged the relay will be energised. (N.B. No K2 present on Technology 150).

Block 11
Flyback power supply Consisting of:T2, U2 (primary board). Uses switching methods to transform and stabilise the voltage obtained from block 4 (filter) and supplies auxiliary voltage to power block 12 (driver) and the hybrid board.

Block 12
IGBT Driver Consisting of: U1A, U1D (primary board). Takes the signal from block 11 (flyback power supply) and, controlled by block 14 (duty cycle maker), makes the signal suitable for piloting block 6 (chopper).

Block 4
Filter Consisting of: C2, C4, C5, C6, C7 (primary board). Converts the pulsed voltage arriving from the rectifier bridge to continuous voltage (N.B. No C7 present on Technology 150).

Block 13
Primary current reader and limiter Consisting of: R15 (primary board). Reads the signal from block 6 (current transformer) and scales it down so it can be processed and compared in block 14 (duty
cycle maker).

Block 5
Chopper Consisting of: Q1, Q2, Q3, Q4 (primary board). Converts the continuous voltage from the filter into a high frequency square wave capable of piloting the power transformer. Regulates the power according to the required welding current/voltage.

Block 14
Duty cycle maker Consisting of: U2 (hybrid board). Processes the information from block 15 (adder) and block 13 (primary current reader and limiter) and produces a square wave with variable duty cycle limiting the primary current to a maximum pre-set value under all circumstances.

Block 6
Current transformer Consisting of:T1 (primary board). The C.T. is used to measure the current circulating in the power transformer primary and transmit the information to block 14 (primary current reader and limiter).

Block 15
Adder Consisting of: U1A, U1D (hybrid board). Gathers all the information from block 13 (primary current reader and limiter), from block 16 (alarms) and from block 18 (current potentiometer), and produces a signal with a suitable voltage for processing by block 14 (duty cycle maker).

Block 7
Power transformer Consisting of:T1. Adjusts the voltage and current to values required for the welding procedure. Also forms galvanic separation of the primary from the secondary (welding circuit from the power supply line).

Block 16
Alarm Block Consisting of: Q5, R11, R14, R17 (control board). When an alarm is detected the power source output current is drastically reduced by making direct adjustments to block 14 (duty cycle maker) and directly changing the reference signal obtained from block 18 (current potentiometer).

Block 8
Secondary diodes Consisting of: D1, D2, D3, D5(secondary board). - D1 and D2 convert the current circulating in the transformer to a single direction, preventing saturation of the nucleus. (N.B.: No D2 on Technology 150).
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TECHNOLOGY 150-170-200-186CE/GE
Block 17
Alarm LED Consisting of: D9 (primary board). It is switched on by block 16 (alarms) in the event of: 1) Triggering of thermostatic capsule on inductance. 2) Triggering of thermostatic capsule on secondary diodes. 3) Triggering due to undervoltage. 4) Triggering due to overvoltage. 5) Short circuit at output (electrode holder clamp and earth cable connected to one another or electrode stuck to piece being welded).

Block 25
Overvoltage safeguard Consisting of: U3A, R62, R68 (primary board). If the main supply voltage exceeds the maximum value this safeguard triggers (a tolerance of approx. 15% of the power supply voltage is allowed: outside this range the safeguard triggers).

Block 23
Undervoltage safeguard Consisting of: U3B, R61, R67(primary board). If the main supply voltage falls below the minimum allowed value this safeguard triggers (a tolerance of approx. 15% of the power supply voltage is allowed: outside this range the safeguard triggers).

Block 18
Current potentiometer Consisting of: R16 (primary board). This is used to set the reference voltage needed to adjust the output current: when the potentiometer knob is turned the cursor voltage varies, thus varying the current from the minimum to the maximum value.

Block 27
Fan Consisting of:V1. Powered directly 230V by block 11 (flyback transformer) and cools the power components.

Block 19
Welding mode function selector Consisting of: SW1 (primary board) The switch is used to select the type of welding procedure: TIG-Lift, Hard or Soft.

Block 28
Short circuit detector Consisting of: U3B (hybrid board). If the welding voltage is below 10V this circuit causes block 30 (arc force) to trigger.

Block 20
Shunt Amplifier Consisting of: U4 (hybrid board) Amplifies the signal arriving from block 10 (shunt inductance), making it suitable for block 21 (maximum current regulator).

Block 29
Hot Start Consisting of: Q2,Q3,C9 (hybrid board). At the start of MMA welding, Hot Start generates a temporary overcurrent based on the current setting made by block 20 (current potentiometer) in order to pre-heat the electrode and prepare the weld pool.

Block 21
Maximum current regulator Consisting of: R13 (primary board) Used to regulate the maximum welding current that can be supplied by the power source.

Block 30
Arc Force Consisting of: Q6, Q7, C14 (hybrid board). If the arc voltage falls below 10V, this block produces a temporary increase in the output current, so as to detach the electrode from the piece after it has become stuck.

Block 22
Secondary diode thermostat Consisting of: ST1 When the temperature of the secondary diode dissipator is too high the thermostat cuts in, sending an alarm signal to block 24 (galvanic separation). It is reset automatically when this alarm condition is no longer present.

Block 31
Short circuit delay Consisting of: U3B (hybrid board). If the output shorting persists this block shuts down the power source via block 16 (alarms).

Block 23
Inductance thermostat Consisting of: ST2 When the temperature of the inductance is too high the thermostat cuts in, sending an alarm signal to block 24 (galvanic separation). It is reset automatically when this alarm condition is no longer present.

Block 24
Galvanic separation Consisting of: ISO3 (primary board). The signals arriving from blocks 22 and 23 (transformer thermostat and inductance thermostat) are separated galvanically and sent to block 16 (alarms) for detection of a possible alarm event.

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TECHNOLOGY 150-170-200-186CE/GE TECHNOLOGY 150-170-200-186CE/GE
ILLUSTRATIONS
Primary board
(1) EMC FILTER (5) CHOPPER (2) RECTIFIER BRIDGE (4) FILTER (25-26) OVER/UNDER VOLAGE SAFEGUARD (19) FUNCTIONS SELECTOR (18) CURRENT POTENTIOMETER

(17) ALARM LED (11) FLY-BACK POWER SUPPLY

(12) DRIVER IGBT

(5) CHOPPER

(3) PRE-CHARGE

HYBRID BOARD

(6) CURRENT TRASFORMER

(24) GALVANIC SEPARATION

Secondary board
(8) SECONDARY DIODES (9) SHUNT (10) SECONDARY EMC FILTER

(8) SECONDARY DIODES

(22) SECONDARY DIODES THERMOSTAT

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TECHNOLOGY 150-170-200-186CE/GE
WIRING DIAGRAMS
General wiring diagram

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TECHNOLOGY 150-170-200-186CE/GE TECHNOLOGY 150-170-200-186CE/GE
Wiring diagram primary board - Power

Schema elettrico scheda primario - Driver

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TECHNOLOGY 150-170-200-186CE/GE
Wiring diagram primary board - Power supply

Wiring diagram primary board - Driver

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TECHNOLOGY 150-170-200-186CE/GE TECHNOLOGY 150-170-200-186CE/GE
Wiring diagram hybrid board

Wiring diagram secondary board

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TECHNOLOGY 150-170-200-186CE/GE

REPAIR GUIDE
EQUIPMENT REQUIRED

1

7

6

3

2

8

4

5

9

ESSENTIAL INSTRUMENTS
1 Dual trace oscilloscope 2 Static load generator 3 Variac 0 - 300v 1500 VA 4 Digital multimeter 5 Differential probe 1/200 6 Hall Probe 7 HV Power supply cod. 802401 (*) cod. 802110 (*) cod. 802402 (*) cod. 802406 (*) cod. 802403 (*)

USEFUL INSTRUMENTS
8 Unsoldering station 9 Miscellaneous tools

(*)The instruments with codes can be supplied by Telwin. The sale price is available on request.
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TECHNOLOGY 150-170-200-186CE/GE TECHNOLOGY 150-170-200-186CE/GE
GENERAL REPAIR INSTRUCTIONS
WARNING: BEFORE PROCEEDING WITH REPAIRS TO THE MACHINE READ THE INSTRUCTION MANUAL CAREFULLY. WARNING: EXTRAORDINARY MAINTENANCE SHOULD BE CARRIED OUT ONLY AND EXCLUSIVELY BY EXPERT OR SKILLED ELECTRICALMECHANICAL PERSONNEL. WARNING: ANY CHECKS CARRIED OUT INSIDE THE MACHINE WHEN IT IS POWERED MAY CAUSE SERIOUS ELECTRIC SHOCK DUE TO DIRECT CONTACTWITH LIVE PARTS.
The following is a list of practical rules which must be strictly adhered to if repairs are to be carried out correctly. A) When handling the active electronic components, the IGBT's and Power DIODES in particular, take elementary antistatic precautions (use antistatic footwear or wrist straps, antistatic working surfaces etc.). B) To ensure the heat flow between the electronic components and the dissipator, place a thin layer of thermo-conductive grease (e.g. COMPOUND GREASIL MS12) between the contact zones. C) The power resistors (should they require replacement) should always be soldered at least 3 mm above the board. D) If silicone is removed from some points on the boards, it should be re-applied. N.B. Use only non-conducting neutral or oximic reticulating silicones (e.g. DOW CORNING 7093). Otherwise, silicone that is placed in contact with points at different potential (rheophores of IGBT's, etc.) should be left to reticulate before the machine is tested. E) When the semiconductor devices are soldered the maximum temperature limits should be respected (normally 300C for no more than 10 seconds). F) It is essential to take the greatest care at each disassembly and assembly stage for the various machine parts. G) Take care to keep the small parts and other pieces that are dismantled from the machine so as to be able to position them in the reverse order when re-assembling (damaged parts should never be omitted but should be replaced, referring to the spare parts list given at the end of this manual). H) The boards (repaired when necessary) and the wiring should never be modified without prior authorisation from Telwin. I) For further information on machine specifications and operation, refer to the Instruction Manual. J) WARNING! When the machine is in operation there are dangerously high voltages on its internal parts so do not touch the boards when the machine is live.

HV POWER SUPPLY MODULE
THE HV POWER SUPPLY is used to ensure operation of the switching power supply (the circuit on the primary board supplying auxiliary voltages), even when the machine is operating at low voltage. It is easy to build using the electrical diagrams in fig. A for reference and using the following components or, alternatively, it can be ordered from Telwin. T1 = insulation transformer 230-230V 50VA(*) D1 = rectifier bridge 36MB 80 (cod. 112357) C1 = electrolytic capacitor 470uF 400V ALL (cod.112514) R1 = resistor 10 ohm 5W 5% R2 = resistor 100K ohm 2W 5% F1 = delayed action fuse 1.5 A Fuse holder 5X20mm Female red and black faston Plastic box.

TROUBLESHOOTING AND REMEDIES
1.0 Disassembling the machine
WARNING! Every operation should be carried out in complete safety with the power supply cable disconnected from the mains outlet: - Undo the 8 screws fastening the 2 plastic covers (4 each) to the front and back (figure 1A). - Undo the 8 screws fastening the top cover to the structure (figure 1B). - Slide out the top cover by pulling gently outwards (figure 1B). After completing the repairs, proceed in the reverse order to reassemble the cover and do not forget to insert the toothed washer on the ground screw.

FIGURE A
ELECTRICAL DIAGRAM FOR POWER SUPPLY (HV OUTPUT):
F1 T1 R1
10 5

D1 R2

2.0 Cleaning the inside of the machine
Using suitably dried compressed air, carefully clean the components of the power source since dirt is a danger to parts subject to high voltages and can damage the galvanic separation between the primary and secondary. To clean the electronic boards we advise decreasing the air pressure to prevent damage to the components. It is therefore important to take special care when cleaning the following parts Fan (fig. 2B) Check whether dirt has been deposited on the front and back air vents or has damaged the correct rotation of the blades, if there is still damage after cleaning replace the fan. Primary board (fig. 3:) - rheofores of IGBT's Q1, Q2, Q3, Q4; - rheofores of recirculating diodes D4, D8; - rheofores of snubber network diodes D1, D6;
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THE INSULATION TRANSFORMER CAN BE REPLACED WITH T WO T R A N S F O R M E R S O F T H E S A M E P OW E R , CONNECTING THE SECONDARIES ACCORDING TO THE FOLLOWING DIAGRAM:

TECHNOLOGY 150-170-200-186CE/GE
- rheofores of opto-couplers ISO1 and ISO2; - rheofores of connectors J4 and J6; Secondary board (fig. 4):) - rheofores of secondary power diodes D1, D2, D3, D5 (N.B. not present on Technology 150); - thermostat ST1 on secondary diode dissipator; - shunt R1. Power transformer and inductance assembly Do this if it is necessary to remove the primary board, otherwise it is possible to clean the part superficially from the side of the secondary board. Parts fastened to the base If the primary and secondary boards are removed (with the diaphragm), carefully clean all the parts fastened to the base, or clean the base partially from the sides of the machine.

4.0 Checking the power and signal wiring
It is important to check that all the connections are in good condition and the connectors are inserted and/or attached correctly. To do this, take the cables between finger and thumb (as close as possible to the fastons or connectors) and pull outwards gently: the cables should not come away from the fastons or connectors. N.B. If the power cables are not tight enough this could cause dangerous overheating.

5.0 Electrical measurements with the machine switched off
A) With the multimeter set on diode testing check the following components (joint voltages not less than 0.2V): rectifier bridges D3, D5 (fig. 3); IGBT's Q1, Q2, Q3, Q4, (no short circuits between collectorgate and collector-emitter (fig. 3); secondary diodes D1, D2, D3, D5 between anode and cathode (fig. 4). The secondary diodes can be tested without removing the primary board, placing a prod on the secondary diode dissipator and the other in sequence on the 2 power transformer output terminals. B) With the multimeter in ohm mode check the following components: resistor R1: 47 ohm (precharge fig. 3). resistors R2, R6: 10 ohm (primary snubber fig. 3). resistor R1: 10 ohm (secondary snubber fig. 4). thermostat continuity test on inductance and secondary dissipator: disconnect connector J2 from the primary board and make sure the resistance between pins 4 and 5 is approx. 0ohm (fig. 4).

3.0 Visual inspection of the machine
Make sure there is no mechanical deformation, dent, or damaged and/or disconnected connector. Make sure the power supply cable has not been damaged or disconnected internally and that the fan works with the machine switched on. Inspect the components and cables for signs of burning or breaks that may endanger operation of the power source. Check the following elements:

Relays K1, K2 primary board (fig. 3) Probable cause: - see main power supply switch. N.B. If the relay contacts are stuck together or dirty, do not attempt to separate them and clean them, just replace the relay. Electrolytic capacitors C2,C4,C6,C7 primary board (fig. 3) Probable cause: - mechanical shock; - machine connected to power supply voltage much higher than the rated value; - broken rheophore on one or more capacitor: the remainder will be overstressed and become damaged by overheating; - ageing after a considerable number of working hours; - overheating caused by thermostatic capsule failure. IGBT's Q1, Q2, Q3, Q4 primary board (fig. 3) 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. Primary diodes D1, D4, D6, D8 primary board (fig. 3) Probable cause: - excessive overheating related to faulty operation. Mode selector switches SW1 and SW3 primaryboard (fig. 3) Probable cause: - mechanical shock. Secondary diodes D1, D2, D3, D5 secondary board (fig. 4) Probable cause: - discontinuation in snubber network; - poorly functioning thermal contact between IGBT and dissipator (e.g. loosened attachment screws: check); - faulty output connection. Shunt R1 secondary board (fig. 6) Check it for colour changes. Probable cause: - overheating due to loosening of the screws connecting the shunt to the PCB. Power transformer and filter inductance Inspect the windings for colour changes. Probable causes: - aging after a substantial number of working hours; - excessive overheating related to faulty operation.
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Current potentiometer R16 (fig. 3) Probable cause: - mechanical shock.

6.0 Electrical measurements with the machine in operation
WARNING! Before proceeding with faultfinding, we should remind you that during these tests the power source is powered and therefore the operator is exposed to the danger of electric shock. The tests described below can be used to check the operation of the power and control parts of the power source.

6.1 Preparation for testing
A) From the primary board, disconnect fastons CN3 (XF+) and CN10 (XF-) for the power transformer (fig. 3). B) On the primary board disconnect the jumper on JP1. C) Connect the HV power supply OUT (code 802403) on the primary board as follows (fig. 3): (+) Positive (clamp) to rheofore of resistor R35 towards JP1 (after removing jumper JP1); - (-) Negative (faston) to negative faston of diode bridge D3. D) Set up the oscilloscope with the voltage probe x100 connected between the rheofore of R40B (collector Q10) towards JP1 (probe) and the negative of diode bridge D3 (earth) to the primary board (fig. 3). E) Position the current potentiometer R16 on maximum (turn clockwise as far as it will go) and switch SW1 to SOFT (as far down as it will go); WARNING! the high frequency voltage will permanently damage any instrument connected to the generator. Before proceeding make very sure that the fastons listed above are disconnected and completely isolated from one another. F) Connect the power supply cable to a single phase variac with variable output 0-300 Vac. WARNING! during testing prevent contact with the metal part of the torch because of the presence of high voltages that are hazardous to the operator.

6.2 Scheduled tests
A) Switch on the HV power supply (HV OUT) and make sure that (fig. 3): - pre-charge relays K1 and K2 close; - the fan starts to turn for the power transformer;

TECHNOLOGY 150-170-200-186CE/GE TECHNOLOGY 150-170-200-186CE/GE
- yellow led alarm is turn off. B) Make sure the waveform shown on the oscilloscope resembles Fig. B. K) Make sure the waveform shown on the oscilloscope resembles fig. D.

FIGURE B
SETTINGS: PROBE x100; 100 V/Div; 10 sec/Div.
VERIFY THAT THE FREQUENCY IS 35KHz 15%; AMPLITUDE IS 450V 10%;

FIGURE D
SETTINGS: PROBE x100; 10V/Div; 10 sec/Div.
VERIFY THAT AMPLITUDE ON CH1 IS 35V 20%;

N.B. if there is no signal it may be necessary to replace the integrated circuit U2 or IGBT Q10 on the primary board (fig. 3). C) Set up the multimeter in volt mode and make sure the primary board has the following voltages: (fig. 3): - between the cathode of diode D32 (+) and the negative of diode bridge D5 (-): equal to +15Vdc 3%; - between pin 3 (+) and the dissipator (-) of U4: equal to +12Vdc 5%; - between pin 3 (+) and pin 1 (-) of U6: equal to -12Vdc 5%; - between pin 8 (+) and pin 7 (-) of ISO1: equal to +26Vdc 5%; - between pin 8 (+) and pin 7 (-) of ISO2: equal to +26Vdc 5%; D) Switch off the HV power supply. E) Set up the oscilloscope with the voltage probe x10 connected between the gate (probe) and the emitter (earth) of IGBT Q4 on the primary board (fig. 3). F) Switch on the HV power supply (HV out) and make sure the waveform displayed on the oscilloscope resembles fig. C.

L) Repeat this test on Q2 as well, using the differential probe. N.B. If the signal is not present there may be a fault in the IGBT's (fig.5). M) Return the variac voltage to 0V, switch off the machine and the HV power supply. N) Disconnect the HV power supply, replace jumper JP1 on the board. O) Switch the machine on again and gradually increase the voltage generated by the variac to 115Vac 5% then make sure an alarm is registered with yellow LED D9 lit up. P) Increase the voltage on the variac to 230Vac and make sure the alarm ceases (yellow LED D9 goes off). Q) Increase the voltage on the variac yet again to 275Vac 5% and make sure the machine registers an alarm again. Return the variac voltage immediately to 230Vac and switch off the machine. N.B. if an alarm persists (and is not caused by a fault in the hybrid board) there could be a fault in opto-isolator ISO3 or integrated circuit U3 on the primary board (fig. 3).

FIGURE C

7.0 Repairs, replacing the boards
SETTINGS: PROBE x10; 10V/Div; 10 sec/Div.
VERIFY THAT POSITIVE AMPLITUDE IS +18V 10%; NEGATIVE AMPLITUDE IS -10V 10%.

If repairing the board is complicated or impossible, it should be completely replaced. The board is identified by a 6-digit code (printed in white on the component side after the initials TW).This is the reference code for requesting a replacement: Telwin may supply boards that are compatible but with different codes. WARNING! before inserting a new board check it carefully for damage that may have occurred in transit. When we supply a board it has already been tested and so if the fault is still present after it has been replaced correctly, check the other machine components. Unless specifically required by the procedure, never alter the board trimmers. 7.1 Removing the primary board (fig. 3) If the fault is in the primary board remove it from the machine structure as follows: - with the machine disconnected from the main power supply disconnect all the wiring from the primary board; - cut any bands restricting the board (e.g. on the power supply cable and primary connections); - undo the screws fastening the front and back panels and remove the panels from the machine structure; - remove the current adjustment knob on the front panel of the machine; - undo the screws fastening the primary board to the machine structure (fig.2B); - remove the primary board by lifting it upwards. N.B. for assembly proceed in the reverse order.

G) Repeat this test on Q1, Q2, Q3 as well. N.B. if the signal is not present there could be a fault in the IGBT driver circuit, specifically ISO1 and ISO2 (fig. 3), or in the hybrid board (fig. 3, in which case we recommend replacing the board). H) Switch off the HV and replace the 2 fastons connecting the primary board and the power transformer (CN3 and CN10). I) Switch on the HV and the variac (initially set to 0V), close the main power supply switch on the machine and gradually increase the voltage generated by the variac until it reaches 26Vac. J) Set up the oscilloscope with the voltage probe x100 connected between the collector (probe) and the emitter (earth) of IGBT Q4 on the primary board (fig. 3).
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TECHNOLOGY 150-170-200-186CE/GE
Please read the procedure for replacing the IGBT's carefully (fig. 3). The 4 IGBT's are attached to 2 different dissipators and whenever a replacement is required, both IGBT's should be replaced. - Unscrew the four (4) nuts that fix the dissipator onto the card; - unscrew the four (4) screws that fix the four (4) IGBT onto the dissipator; - unscrew the two (2) screws that fix the two diode bridges onto the dissipator; - remove the four (4) IGBT and the two (2) diode bridges by unwelding the reophores, then remove tin from the p r i n t e d plates; - remove dissipator from card. Before making the replacement make sure the components piloting the IGBT's are not also damaged: - with the multimeter set in ohm mode make sure there is no st rd short circuit on the PCB between the 1 and 3 bump contacts (between gate and emitter) corresponding to each component; - alternatively, resistors R3, R4, R7, R8 could have burst and/or diodes D11, D12, D15, D16 may be unable to function at the correct Zener voltage (this should have shown up in the preliminary tests); - clean any irregularity or dirt from the dissipators. If the IGBT's have burst the dissipators may have been irreversibly damaged: in this case they should be replaced; - apply thermo-conductive grease following the general instructions. - prepare the components for replacement. For the IGBT's, bend the rheofores at 90 (never bend and/or place the parts under tension near the case). - position the components on the dissipator with the fastening screws, but do not tighten the screws completely - join the dissipator/component assembly to the printed board, inserting all the rheofores in the bump contacts and the threaded spacers on the 4 attachment holes. - attach the dissipators with the nuts and lock them once and for all in the following order: - the nuts fastening the dissipators to the printed circuit with a torque wrench setting of 2 Nm 20%; - the screws fastening the rectifiers to the dissipators with a torque wrench setting of 2 Nm 20%; - the screws fastening the IGBT's to the dissipators with a torque wrench setting of 1 Nm 20%. - solder the terminals taking care not to let the solder run along them. - on the component side cut away the protruding part of the rheofores and check they are not shorted (especially the gate and emitter). NOTE. The 4 IGBT's should belong to the same selection kit supplied by Telwin. 7.2 Removing the hybrid board (fig. 3) If the fault is in the hybrid board remove it from the primary board as follows: - with the primary board removed from the machine structure unsolder the rheofores from the hybrid board on the soldering side; - remove the solder from the bump contacts on the PCB; - remove the hybrid board from the primary board; N.B. for assembly proceed in the reverse order. If the fault is in the hybrid board we strongly advise replacing it without further intervention. 7.3 Removing the secondary board (fig. 4) If the fault is in the secondary board, unless the dissipator has been damaged by a destructive explosion of the diodes, the board does not generally need to be removed and the diodes can be replaced directly with the board mounted on the machine. In any case, it should be specified that to remove it, it is necessary to
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separate the base from the machine structure as follows: - with the machine disconnected from the main supply undo the 4 side screws (2 on the front and 2 on the back) that attach the board to the base; - turn the machine upside down and undo the 2 screws fastening the base to the structure; - finally remove the base from the structure. Complete removal of the secondary board from the structure: - undo the 4 side screws fastening the board to the machine structure; - remove the 3 hexagonal-head screws that fasten the shunt and connect the power transformer; - disconnect the wiring for the thermostatic capsule. N.B. for assembly proceed in the reverse order. Take special note of the procedure for replacing the secondary diodes: The 4 secondary DIODES are attached to the dissipator and whenever a replacement is made, all 4 diodes should be replaced: - remove the 4 diodes by unsoldering the rheofores and also remove the solder from the bump contacts on the PCB; - clean any irregularities or dirt from the dissipators. If the diodes have burst the dissipator may be irreparably damaged: in such a case it should be replaced; - apply thermoconductive paste following the general instructions; - place the dissipator with the new components on the bump contacts of the PCB and fasten it down with the screws (torque wrench setting 1 Nm 20%); - solder the terminals taking care not to let the solder run along them; - on the soldering side cut the protruding part of the rheofores and make sure they have not shorted (between cathode and anode). N.B. make sure that resistor R1 and capacitor C1 of the snubber are soldered correctly (fig. 3).

TESTING THE MACHINE
Tests should be carried out on the assembled machine before closing it with the top cover. During tests with the machine in operation never commute the selectors or activate the ohmic load contactor. WARNING! Before proceeding to test the machine, we should remind you that during these tests the power source is powered and therefore the operator is exposed to the danger of electric shock. The tests given below are used to verify power source operation under load.

1.1 Preparation for testing
A) Connect the machine to the static load generator (code 802110) using cables fitted with the appropriate dinse connectors. B) Set up the dual trace oscilloscope with the voltage probe CH1x100 connected between the collector (probe) and the emitter of Q4 (earth) on the primary board (figure 3). C) Pass the current probe of the Hall effect transducer along the cable connecting the power transformer at faston CN10 with the reference arrow pointing into CN10. D) Lastly, connect the Hall Probe and the current probe to the oscilloscope. E) Set up a multimeter in DC volt mode and connect the prods to the OUT+ and OUT- dinse connections. F) On the front panel set switch SW1 to SOFT (as low as it will go). WARNING! the high frequency voltage will permanently damage any instrument connected to the generator. Before proceeding make very sure that the fastons listed above are disconnected and completely isolated from one another.

TECHNOLOGY 150-170-200-186CE/GE TECHNOLOGY 150-170-200-186CE/GE
G) Connect the power supply cable to the 230Vac power supply. WARNING! during testing prevent contact with the metal part of the torch because of the presence of high voltages that are hazardous to the operator. C) Intermediate load test: - set up the ohmic load with the switch settings as in the table in fig. G; - on the front panel position the current potentiometer on approx. 80A; - start up the ohmic load and make sure that: - the waveforms displayed on the oscillscope resemble those in Fig. G; - the output current is equal to +80Adc 10% and the output voltage is equal to +23.2.Vdc 10%. - switch off the ohmic load and switch off the main switch.

1.2 Scheduled tests
A) Loadless test: Switch on the machine, gradually increase the power supply voltage from 0V to 230Vac and make sure that: - the pre-charge relays on the primary board close; - the fan starts operating correctly; - the waveform displayed on the oscilloscope resembles Fig. E and the frequency is equal to +32.5KHz 20%; - the output voltage over dinse + and dinse is equal to 95Vdc 10%.

G FIGURE E
SETTINGS: PROBE CH1 x100; 100 V/Div; PROBE CH4 =20A; 10mV/Div; 10 sec/Div.
VERIFY THAT THE FREQUENCY IS 60KHz 5%; AMPLITUDE CH1 IS 340V 10%; AMPLITUDE CH4 IS 26A 20%;

FIGURE E
SETTINGS: PROBE CH1 x100; 100 V/Div; PROBE CH4 =1A; 10mV/Div; 105 sec/Div.
VERIFY THAT THE FREQUENCY IS 60KHz 5%; AMPLITUDE CH1 IS 340V 10%;

1 2 3 4 5 6 2 2 2 2 1 0

Number switch Position switch

B) Rated load test: - set up the ohmic load with the switch settings as in the table in fig. G; - on the front panel position the current potentiometer on minimum (turn anti-clockwise as far as it will go); - switch on the main switch; - start up on the ohmic load and make sure that: - the waveforms displayed on the oscilloscope resemble those in Fig. F; - the output current is equal to +5Adc20% and the output voltage is equal to +20.2Vdc10%. - switch off the ohmic load and switch off the main switch.

A) Rated load test: - the ohmic load with the switch settings according to the relevant Technology model (see tables in Figs. H, I, J, K); - on the front panel position the current potentiometer on maximum (turn clockwise as far as it will go) - start up on the ohmic load and make sure that: For the Technology 150 - the waveforms displayed on the oscillscope resemble those in Fig. H; - the output current is equal to +130Adc 3% and the output voltage is equal to +25.2Vdc 5%; if the output current reading is not 130A 3%, adjust the current using trimmer IMAX R13 on the primary board (fig. 3).

FIGURE F E
SETTINGS: PROBE CH1 x100; 100 V/Div; PROBE CH4 =5A; 10mV/Div; 10 sec/Div.
VERIFY THAT THE FREQUENCY IS 60KHz 5%; AMPLITUDE CH1 IS 340V 10%; AMPLITUDE CH4 IS 7A 20%;

H FIGURE E

SETTINGS: PROBE CH1 x100; 100 V/Div; PROBE CH4 =20A; 10mV/Div; 10 sec/Div.
VERIFY THAT THE FREQUENCY IS 32.5KHz 20%; AMPLITUDE CH1 IS 340V 10%; AMPLITUDE CH4 IS 56A 10%;

1 2 3 4 5 6 1 0 0 0 0 0

Number switch Position switch
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1 2 3 4 5 6 3 3 3 2 2 2

Number switch Position switch

TECHNOLOGY 150-170-200-186CE/GE
For the Technology 170 - the waveforms displayed on the oscillscope resemble those in Fig. I; - the output current is equal to +160Adc 3% and the output voltage is equal to +26.4Vdc 5%; if the output current reading is not 160A 3%, adjust the current using trimmer IMAX R13 on the primary board (fig. 3).

K FIGURE E
SETTINGS: PROBE CH1 x100; 100 V/Div; PROBE CH4 =20A; 10mV/Div; 10 sec/Div.
VERIFY THAT THE FREQUENCY IS 32.5KHz 20%; AMPLITUDE CH1 IS 340V 10%; AMPLITUDE CH4 IS 58A 10%;

I FIGURE E
SETTINGS: PROBE CH1 x100; 100 V/Div; PROBE CH4 =20A; 10mV/Div; 10 sec/Div.
VERIFY THAT THE FREQUENCY IS 32.5KHz 20%; AMPLITUDE CH1 IS 340V 10%; AMPLITUDE CH4 IS 60A 10%;

1 2 3 4 5 6 3 3 3 2 2 2

Number switch Position switch

- switch off the ohmic load and switch off the main switch. E) Checking the secondary diode voltages: - set up the dual trace oscilloscope, connecting probe CH1 x 100 to the anode of diode D1 or D2 and probe CH2x100 to the anode of diode D3 or D5. Earth connections are both made to the secondary dissipator; - remove the multimeter from the OUT+ and OUT- bump contacts; - set up the ohmic load with the switch settings according to the relevant Technology model (see tables at point 1.2D); - on the front panel position the current potentiometer R7 to the maximum (turn the knob clockwise as far as it will go) and switch on the main switch; - activate the static load generator and make sure that the waveforms displayed on the oscilloscope resemble those in fig. L; - deactivate the static load generator and switch off the main switch.

1 2 3 4 5 6 3 3 3 2 2 2

Number switch Position switch

For the Technology 200 - the waveforms displayed on the oscillscope resemble those in Fig. J; - the output current is equal to +180Adc 3% and the output voltage is equal to +27.7Vdc 5%; if the output current reading is not 180A 3%, adjust the current using trimmer IMAX R13 on the primary board (fig. 3).

J FIGURE E
SETTINGS: PROBE CH1 x100; 100 V/Div; PROBE CH4 =20A; 10mV/Div; 10 sec/Div.
VERIFY THAT THE FREQUENCY IS 32.5KHz 20%; AMPLITUDE CH1 IS 340V 10%; AMPLITUDE CH4 IS 60A 10%;

L FIGURE E
SETTINGS: PROBE CH1 x100; 50V/Div; PROBE CH2 x100; 50V/Div; 10 sec/Div.
VERIFY THAT REVERSE AMPLITUDE ON CH1 DOES NOT EXCEED 250V. REVERSE AMPLITUDE ON CH2 DOES NOT EXCEED 250V.

1 2 3 4 5 6 3 3 3 3 3 2

Number switch Position switch

1.3 Operational tests
For the Technology 186CE/GE - the waveforms displayed on the oscillscope resemble those in Fig. K; - the output current is equal to +145Adc 3% and the output voltage is equal to +25.8Vdc 5%; if the output current reading is not 145A 3%, adjust the current using trimmer IMAX R13 on the primary board (fig. 3). A)Arc Force test Set up the ohmic load as shown in the table in Fig. G and the current potentiometer on approx. 80A. Position switch SW1 on HARD (in the centre), start the ohmic load and make sure the output current reading shows approx. 110A 10% then returns to the current setting . B)Running time test and closing the machine On the front panel set switch SW1 to SOFT (as low as it will go and the welding current to maximum). Under the relevant load
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TECHNOLOGY 150-170-200-186CE/GE TECHNOLOGY 150-170-200-186CE/GE
conditions for the particular Technology model (see tables at point 1.2 D), switch on the machine and leave it running until the thermostatic capsules trigger (machine in alarm). After making sure the internal wiring is positioned correctly assemble the machine once and for all. C)Welding test MMA: with the machine set up according to the instructions in the handbook make a test weld with an electrode diam. 2.5 and the current setting at 80A. Monitor the dynamic behaviour of the power source, also checking for the presence of the Arc Force SW1 on HARD (in the centre)

ILLUSTRATIONS
FIG. 1A
SCREWS FASTENING BACK PANEL SCREWS FASTENING FRONT PANEL

SCRAWS FASTENING BACK PANEL

SCREWS FASTENING FRONT PANEL

FIG. 1B
TO COVER SCREWS

TOP COVER SCREWS

TOP COVER SCREWS

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TECHNOLOGY 150-170-200-186CE/GE
FIG. 2A
D9 YELLOW LED ALARM SW1 SWITCH SELECTION TIG/LIFT-HARD-SOFT

CURRENT POTENTIOMETER

BOTTOM COVER SCREWS

BOTTOM COVER SCREWS

POSITIVE DINSE

BOTTOM NEGATIVE DINSE COVER SCREWS

FIG. 2B
GENERAL SWITCH MAINS CABLE

FAN

BOTTOM COVER SCREWS

BOTTOM COVER SCREWS

- 18 -

TECHNOLOGY 150-170-200-186CE/GE TECHNOLOGY 150-170-200-186CE/GE
FIG. 3
D4 D8 R6 Q4, Q3 CN10 D5, D3 C7, C2, C4, C6 JP1 U2 R40B Q10 SW1 R16

ISO2, ISO1

Q2, Q1

R2 CN3

R1

K2, K1

HYBRID BOARD

R13

D32

U4

U6

D9

FIG. 4

D1, D2

R1, C1

SHUNT R1

D3, D5

ST1 - 19 -

THERMOSTAT CABLE

TECHNOLOGY 150-170-200-186CE/GE
ELENCO PEZZI DI RICAMBIO - LISTE PIECES DETACHEES SPARE PARTS LIST - ERSATZTEILLISTE - PIEZAS DE REPUESTO
Esploso macchina, Dessin appareil, Machine drawing, Explosions Zeichnung des Gerts, Diseo seccionado maquina.

15 25 27 19

13 8 16 20

1

5

21

14

10

7

4

2

3

12

23

17

26

6

9

18

11

24

22

Per richiedere i pezzi di ricambio senza codice precisare: codice del modello; il numero di matricola; numero di riferimento del particolare sull'elenco ricambi. Pour avoir les pieces detachees, dont manque la reference, il faudra preciser: modele, logo et tension de I'appareil; denomination de la piece; numero de matricule. When requesting spare parts without any reference, pls specify: model-brand and voltage of machine; list reference number of the item; registration number. Wenn Sie einen Ersatzteil, der ohne Artikel Nummer ist, benoetigen, bestimmen Sie bitte Folgendes: Modell-zeichen und Spannung des Geraetes; Teilliste Nuemmer; Registriernummer. Por pedir una pieza de repuesto sin referencia precisar: modelo-marca e tension de la maquina; numero di riferimento de lista; numero di matricula.

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TECHNOLOGY 150-170-200-186CE/GE TECHNOLOGY 150-170-200-186CE/GE
REF.
ELENCO PEZZI DI RICAMBIO PIECES DETACHEES SPARE PARTS LIST ERSATZTEILLISTE PIEZAS DE REPUESTO

REF.

ELENCO PEZZI DI RICAMBIO PIECES DETACHEES SPARE PARTS LIST ERSATZTEILLISTE PIEZAS DE REPUESTO

REF.

ELENCO PEZZI DI RICAMBIO PIECES DETACHEES SPARE PARTS LIST ERSATZTEILLISTE PIEZAS DE REPUESTO

REF.

ELENCO PEZZI DI RICAMBIO PIECES DETACHEES SPARE PARTS LIST ERSATZTEILLISTE PIEZAS DE REPUESTO

REF.

ELENCO PEZZI DI RICAMBIO PIECES DETACHEES SPARE PARTS LIST ERSATZTEILLISTE PIEZAS DE REPUESTO

1 2 3 4 5 6 7 8 9

Potenziometro Potentiometre Potentiometer Potentiometer Potenciometro Resistenza Resistance Resistor Wiederstand Resistencia Rele' Relais Relais Relais Relais Raddrizzatore Monofase Redresseur Monophase Single-phase Rectifier Einphasiger Gleichrichter Rectificador Monofasico Condensatore Condensateur Capacitor Kondensator Capacitor Condensatore Condensateur Capacitor Kondensator Condensador Interruttore Interrupteur Switch Schalter Interruptor Deviatore Gareur Switch Schalter Interruptor Termostato Thermostat Thermal Switch Thermostat

10 11 12 13 14 15 16 17 18

Cavo Alim. Cable Alim. Mains Cable Netzkabe Cable Alim. Ventilatore Ventilateur Fan Ventilator Ventilador Trasformatore Di Corrente Ta Transformateur De Courant Ta Current Transformer Ta Stromwandler Ta Transformador De Corriente Ta Fibbia Boucle Buckle Schnalle Hebilla Pressacavo Presse Cable Cable Bushing Kabelhalter Prensa Cable Cinghia Courroie Belt Gurt Correa Cornice Cadre Frame Rahmen Marco Frontale Partie Frontal Front Panel Geraetefront Frontal Retro Partie Arriere Back Panel Rueckseite

19 20 21 22 23 24 25 26 27

Fondo Chassis Bottom Bodenteil Base Presa Dinse Prise Dix Dinse Socket Dinse Steckdose Enchufe Dinse Kit Diodi-igbt-resistenza Kit Diodes-igbt-resistance Kit Diodes-igbt-resistance Kit Diodes-igbt-wiederstand Kit Diodos-igbt-resistencia Kit Scheda Secondario Kit Fiche Secondaire Kit Secondary Pcb Kit Sekundaertrafokarte Kit Tarjeta Secundario Kit Scheda Primario Kit Fiche Primaire Kit Primary Pcb Kit Primrtrafokarte Kit Tarjeta Primario Kit Diodo Kit Diode Kit Diode Kit Diode Kit Diodo Kit Manopola Kit Poignee Knob Kit Griff Kit Kit Manija Kit Trasformatore + Induttanza Kit Tranformateur + Reactance Kit Transformer + Reactance Kit Trafo + Reaktanz Kit Transformador + Reactancia Kit Mantello Kit Capot Kit Cover Kit Deckel

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. Please fill in this sheet as accurately as possible and send it to Telwin. Thank you in advance for your co-operation!
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TECHNOLOGY 150-170-200-186CE/GE

Official servicing centers Repairing sheet
Date: Inverter model: Serial number: Company: Technician: 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 Description:

Dirty grade Dirty inside the machine Description:
Kind of failure Component ref.

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

Substitution of primary circuit board: yes Substitution of primary control board: yes Troubles evinced during repair :

no 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: [email protected] http://www.telwin.com