Cod. 988672
CE/GE 175-210-188 GY TECHNOLO 142 TECNICA 140.1
inver ter
TROUBLESHOOTING AND REPAIR MANUAL CONTENTS
PAGE
OPERATION AND WIRING DIAGRAMS................ 2 Block diagram 2 Analysis of the block diagram 3 Illustrations 5 Wiring diagrams 6 REPAIR GUIDE.......................................................11 Equipment required 11 General repair instructions 12 Troubleshooting and remedies 12 Testing the machine 15 Illustrations 18 SPARE PARTS LIST...............................................19 REPAIR SHEET......................................................23
“reparation
no
problem !”
-2-
25
11
28
26
AUXILIARY SUPPLY
POWER SUPPLY LED
3
27 19
UNDERVOLTAGE SAFEGUARD
t
ALARM BLOCK
16
15
V
18
DUTY CYCLE MAKER
TRANSFORMER PILOT
PRIMARY CURRENT READER AND LIMITER
14
DRIVER IGBT
SEPARATOR TRANSFORMER
6
CURRENT TRANSFORMER
13
5
CHOPPER
4
FILTER
SHUNT AMPLIFIER
20
ALARM LED
CONTROL
17
22
TIG -LIFT
MMA
WELDING PROCEDURE FUNCTION SELECTOR
21
CURRENT POTENTIOMETER
ADDER
MAXIMUM CURRENT ADJUSTMENT
10
SECONDARY EMC FILTER
23
9
INDUCTANCE AND SHUNT
+
24
29
FAN
TERTIARY SUPPLY
12
8
SECONDARY DIODES
7
POWER TRANSFORMER
|
POWER TRANSFORMER THERMOSTAT
2
1
PRE-CHARGE
+
SECONDARY DIODE THERMOSTAT
RECTIFIER BRIDGE
EMC FILTER
-
INPUT
OUTPUT
TECHNOLOGY 175-210-188CE/GE
OPERATION AND WIRING DIAGRAMS
BLOCK DIAGRAM
TECHNOLOGY 175-210-188CE/GE Block 9
ANALYSIS OF THE BLOCK DIAGRAM
Inductance and shunt Consisting of: L1, R38. The inductance levels the secondary board diodes' output current making it practically continuous/direct. The shunt reads the current circulating in the inductance and sends it to block 24 (shunt amplifier), which will process the data.
NOTE: Unless indicated otherwise, it should be assumed that the components are assembled on the power board.
Block 1 EMC Filter Consisting of: C24, C25, C26, L2. Prevents noise from the machine from being transmitted along the main power line and vice versa.
Block 10 Secondary EMC Filter Consisting of: C21, C22. Prevents noise from the power source from being transmitted through the welding cables and vice versa.
Block 2 Rectifier bridge Consisting of: D31, D32. Converts the mains alternating voltage into continuous pulsed voltage.
Block 11 Auxiliary supply Constisting of: T2, D1, Q2, U5 Takes and stabilizes the voltage coming from block 2 (rectifier bridge) and makes it suitable to supply correctly: block x (supply led) block x (transformer separator) and block 3 (precharge).
Block 3 Pre-charge Consisting of: K1, K2, R40. Prevents the formation of high transitory currents that could damage the main power switch, the rectifier bridge and the electrolytic capacitors. When the power source is switched on the relay K1 and K2 are de-energised, capacitors C27, C29, C30, C31 are then charged by R40 When the capacitors are charged the relay is energised.
Block 12 Tertiary supply Constisting of: D11, D57, Q0,D8 Takes and stabilizes the voltage coming from tertiary wiring block 7 (power transformer) and makes it suitable to supply correctly block x (fans) and block 3 (pre-charge).
Block 13
Block 4
Separator transformer
Filter Consisting of: C27, C29, C30, C31. Converts the pulsed voltage from the rectifier bridge into continuous voltage.
Consisting of: T3. Supplies two signals, which are separated galvanically from one another, that will be sent to power block 14 (driver).
Block 5 Block 14
Chopper Consisting of: Q6, Q7, Q8, Q9. 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.
Driver Consisting of: Q5, D19, D20, Q10, D25, D26. Takes the signal from block 13 (flyback power supply) and, controlled by block 15 (duty cycle maker), makes the signal suitable for piloting block 5 (chopper).
Block 15
Block 6
Transformer Pilot
Current transformer Consisting of: T1. The C.T. is used to measure the current circulating in the power transformer primary and transmit the information to block 17 (primary current reader and limiter).
Consisting of: Q4, D14, D15, D16. Amplifies the signal arriving from block 16 (duty cycle maker), needed to pilot block 13 (separator transformer).
Block 16
Block 7
Duty cycle maker Consisting of: U2 (control board). Processes the information from block 17 (adder) and block 18 (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.
Power transformer Consisting of: T4. 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 17
Block 8
Adder Consisting of: U1C (control board). Gathers all the information from block 18 (primary current reader and limiter), from block 19 (alarms) and from block 21 (current potentiometer), and produces a signal with a suitable voltage for processing by block 16 (duty cycle maker).
Secondary diodes Consisting of: D46, D47, D48, D49, D51. D46, D47, D48 converts the current circulating in the transformer to a single direction, preventing saturation of the nucleus. D49, D51 recirculate the inductance output current (block 9) when the IGBT's are not conducting, bypassing the power transformer (block 7). -3-
TECHNOLOGY 175-210-188CE/GE Block 18
Block 27
Primary current reader and limiter Consisting of: R79, R80, R81, R82, R83, R84 (control board). Reads the signal from block 6 (current transformer) and scales it down so it can be processed and compared in block 16.
Block 19
Undervoltage safeguard Consisting of: R7, R9 and part of control 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).
Alarm Block Consisting of: U1A (control board). When an alarm is detected the power source output current is drastically reduced by making direct adjustments to block 16 (duty cycle maker) and directly changing the reference signal obtained from block 21 (current potentiometer).
Power supply LED Consisting of: D43. Indicates when the power source is correctly powered and ready for use.
Block 28
Block 20
Block 29
Alarm LED Consisting of: D39. It is switched on by block 19 (alarms) in the event of: 1) Triggering of thermostatic capsule/thermostat on power transformer.
Fan Consisting of: V1, V2. Powered directly by block 12 (Tertiary supply) and cools the power components.
2) Triggering of thermostatic capsule on secondary diodes. 3) Triggering due to undervoltage. 4) Short circuit at output (electrode holder clamp and earth cable connected to one another or electrode stuck to piece being welded).
Block 21 Current potentiometer Consisting of: R49. 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 22 Welding procedure function selector Consisting of: SW1 The switch is used to select the type of welding process: MMA, TIG-LIFT.
Block 23 Maximum current adjustment Consisting of: R48, R55. Used to adjust the maximum cutting current to be supplied by the power source.
Block 24 Shunt Amplifier Consisting of: U3A (control board) Amplifies the signal from block 9 (inductance shunt) and makes it appropriate for block 17 ( Adder).
Block 25 Power transformer thermostat Consisting of: ST2. When the temperature of the power transformer is too high, the thermostat transmit the information to block 19 (Alarm Block). It is reset automatically after the alarm condition has ceased.
Block 26 Secondary diode thermostat Consisting of: ST1 When the temperature of the secondary diode dissipator reaches a given temperature the thermostat cuts in, sending an alarm signal to block 19 (Alarm Block). It is reset automatically when this alarm condition is no longer present. -4-
TECHNOLOGY 175-210-188CE/GE ILLUSTRATIONS Power board (21) CURRENT POTENTIOMETER
(28) POWER SUPPLY LED
(20) ALARM LED
(22) WELDING PROCEDURE FUNCTION SELECTOR
(10) SECONDARY FILTER EMC
(9) INDUCTANCE AND SHUNT
CONTROL BOARD
(8) SECONDARY DIODES
(7) POWER TRANSFORMER
(11) AUXILIARY POWER SUPPLY (6) CURRENT TRANSFORMER
(15) TRANSFORMER PILOT
(2) PRE-CHARGE
(13) SEPARATOR TRANSFORMER
(3) RECTIFIER BRIDGE
(5) CHOPPER
(1) PRIMARY EMC FILTRE
(4) FILTER
-5-
1
4
L1
N (L2 )
PE
S1 ON /O F F
5
2
-6-
V2 F an
V1 F an
ON LY FOR GE VER S O I N
Indu ttance
L1
V2-
V 2+
V1-
V1+
CN9
CN4
CN11
POW E R PCB
SH -
R 38 S hun t
J22
J21
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
J7
OU T -
O U T+
SW LED GND
+5V +17V8 D R+ GND T A+ TA SH S H+ VO L T VO L T+ PO T _ IN T AR+ T AR VCH ECK FAU L T
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
J3
CON T RO L PCB
TECHNOLOGY 175-210-188CE/GE
WIRING DIAGRAMS Wiring general diagram - TECHNOLOGY 175 - 210 -188 CE/GE
J8
J7
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
F o r i 22 pa s so 2 .5
F o r i_ 12 pa s so 2 .5
NM . .
CN8
T A+ TA SH S H+ VO L T VO L T+ PO T IN T A R+ TAR VC H E C K FAU L T C A DM C AD A C AD 1 C AD 2 SW LED
D R+
B
T P 11
CO R R
T P 21
D32 V .T .
D is s p i atore
H1
D31 V .T .
R 13 NM . .
R 12 NM . .
R 55 V .T .
C 35 1u 63V M K T
T P 16
R 56 NM . .
R 48 47K 20 T 0W 5 10%
M I AX
C26 4n7 250V K P
T P 18 T P 19 T P 20
B
+5V
R 49 10K L IN 0W 2 10%
T P8
L2 295uH
C25 4n7 250V K P
T P4 T P5 T P6
R 39 1M 0W 5 5%
+5V +17V 8
Fas ton-M 6 ,3x0 ,8
CN11
Fas ton-M 6 ,3x0 ,8
CN9
C24 1u 275V M K P
Fas ton-M 6 ,3x0 ,8
CN4
T P1 T P2 T P3
B
C28 NM . .
T P 17
JP 1 V .T .
+5V
K1 V .T .
K2 V .T .
R 40 47R 8W 5%
470u 450V A ll
NM . .
NM . .
R 14 3K 3 5W 10%
T P 22
SGW 30N60
R 57 NM . .
JP 2 V .T .
T ECHNO LOG Y 188G E /C E
SGW 30N60
D 40 1N 4148
T P 23
C27 220n 630V M K P
D39 Ga i llo 5mm
+17V8
F15246B
VCH ECK
DR+
AC+ AC -
R E LE _K1_A R E LE _K1_B
R E LE _K2_A R E LE _K2_B
T P7
C44 100u 25V A ll
P ower board T echno o l gy_B
C31 V .T .
K1 = 15Vdc 45mA /250V 16A K2 = 15Vdc 45mA /250V 16A
D31 = 36M B 100A D32 = N M . .
C30 V .T .
K1 = 15Vdc 45mA /250V 16A K2 = 15Vdc 45mA /250V 16A
D31 =G B PC3508 /10 D32 =G B PC3508 /10
R 50 2K 2 0W 25 5%
C29 V .T .
470u 450V A ll
680u 400V A ll
470u 400V A ll
ON
O FF
O FF
JP 1
MMA
TG I
R E LP
B
T P 24
T P 10
+17V8 T P 9
S P+
SP -
T P 38
T P 37 R 46 1R 0W 25 5%
R 47 1R 0W 25 5%
H2
Q6 V .T .
F15246C
R E LP
S P+
SP -
Q8 V .T .
Q9 V .T .
D is s p i atore
H3
Q7 V .T .
O FF
ON
ON
JP 2
D is s p i atore
T P 40 R 43 1R 0W 25 5%
T P 39 R 42 1R 0W 25 5%
D41 1N4148
SW 1 1B 11
E M E T _H
SGW 30N60
G A T E _H
T ECHNO LOG Y 210
EM E T _ L
T ECHNO LOG Y 175
K1 , K 2
GA T E _ L
K1 = 15Vdc 45mA /250V 16A K2 = 15Vdc 45mA /250V 16A
T A+
D31 , D32
R 55
C34 10n 630V K P
R 45 20R 13W 5%
C33 10n 630V K P
R 44 20R 13W 5%
T R A FO _P P
T R A FO _PN
Power board T echno o l gy_C
D36 NM . .
D34 NM . .
33K 0W 25 5%
10K 0W 25 5%
27K 0W 25 5%
TA -
D31 =G B PC3508 /10 D32 =G B PC3508 /10
SH -
C29 ,C30 ,C31
S H+
C28
VO L T -
G I B T Q6 ,Q7 , Q8 ,Q9
T E RM C I O
-7-
VO L T +
MOD E L
D38 M U R 1560
D35 R U R P 860
D37 M U R 1560
D33 R U R P 860
TECHNOLOGY 175-210-188CE/GE
Wiring diagram power board - primary
D R+
SP -
S P+
AC -
AC+
C 41 33u 25V A ll
C11 100u 63V A ll
D57 B Y V27-200
D11 B Y V27-200
B
B
R 26 1K 0W 25 5%
R 25 220R 0W 25 5%
C 15 1u 63V M K T
B
D 16 B Y V 27 -200
D 15 10V 0W 4 5%
Q4 IR FD 110
1
8
T3 T I 117303
+17V 8
C38 1u 63V M K T
C37 1n 100V X7R
D43 Verde 5mm
R 51 3K 3 0W 5 5%
T P 34
C9 1u 63V M K T
D10 B Y V27-200
D 14 10V 0W 4 5%
C10 1u 63V M K T
C36 T P 29 1n 100V X7R
T2 230 /18 4VA
D1 W 02G
T P 25
6
5
3
4
C39 1u 63V M K T
C1 470u 50V A ll
R1 470R 2W 5%
C2 10u 25V A ll
C 17 1u 63V M K T
D 17 B Y V 27 -200
120R 0W 25 5%
R 27
D 25 B Y V 27 -200
C 16 1u 63V M K T
D 18 B Y V 27 -200
120R 0W 25 5%
R 28
D 19 B Y V 27 -200
C3 470u 25V A ll
1
R 34 470R 0W 25 5%
D 26 B Y V 27 -200
R 29 470R 0W 25 5%
1
R 32 1K 0W 25 5%
C 18 NM . . Q 10 BC 327
R 33 10R 0W 25 5%
D 53 NM . .
R 30 1K 0W 25 5%
C 19 NM . . Q5 BC 327
10R 0w25 5%
C43 47u 25V A ll
T P 28
R9 12K 0W 25 5%
R 31
1
10V 0W 4 5%
D7
C40 33u 25V A ll
R 58 22R 0W 5 5%
D 52 NM . .
D8 15V 0W 4 2%
H4 Q0 T IP 122
D 20 B Y V 27 -200
R8 3K 3 0W 5 5%
D3 18V 1W 5%
H4
Q2 T IP 50
T P 26
IN
U5
-V1
V1 12Vdc
D24 18V 0W 4 5%
D23 18V 0W 4 5%
D22 18V 0W 4 5%
T P 33
T P 31
T P 32
T P 30
VCH ECK
-V2
+V2
C6 10u 25V A ll
T P 27 +5V
D21 18V 0W 4 5%
+V1
B
LM 78L05 3 OU T
D4 1N4148
GND 2
D2 1N4004
+17V8
EM E T _L
GA T E _L
EM E T _H
GA T E _H
V2 12Vdc
C42 33u 25V A ll
D56 NM . .
B
2
D6 1N4148
10V 0W 4 5%
D55
R 59 10K 0W 25 5%
+17V8
1 3
C14 NM . .
2 3 2
-83
20V
C8 100N 63V M K T
2 no so d l er
Q1 M P S A13
D54 1N4148
1 no so d l er
R E LE _K2_B
R E LE _K2_A
R E LP
R E LE _K1_B
R E LE _K1_A
TECHNOLOGY 175-210-188CE/GE
Wiring diagram power board - power / driver
T R A FO _P N
J9
A
2
B
3
T1 1 /200 25A
F ILO T A
1
T R A FO _P P
4
J10
T4 T ras fo_1 /2
S T2 110 C °
J6
J5
T P 12 T P 13
T P 15 T P 14
C 32 1n5 630V K P
R 41 10R 5W 5%
T A+
TA -
SP -
S P+
3 D 27 NM . .
D 48 V .T .
D47 V .T .
3
H4
D46 V .T .
3
D44 NM . .
D47 = S T T H 6003CW
D47 = N M . .
D46 = S T T H 6003CW D48 = S T T H 6003CW
T ECHNO LOG Y 210 D46 = N M . . T ECNO LOG Y 188CE /G E D48 = N M . .
D47 = N M . .
D47
T ECHNO LOG Y 175
D46 , D48 D46 = S T T H 6003CW D48 = S T T H 6003CW
MOD E L
1 2 1 2 1
-92
1
3
2 D49 S T T H 6003CW
D29 NM . .
J1 IN /OU T
J2 IN /OU T
1
B
S T1 80°C
D50 NM . . H5
3
R E LP
2
1
3
2 D51 S T T H 6003CW
L1 11uH
D30 NM . .
B
R 38 180A = 210mV
C22 10n 300V M K P
so d l er
JP 4
C21 10n 300V M K P
B
Q3 BC337
T P 36
R 60 1K 0W 25 5%
T P 35
R 37 100K 0W 25 5%
C20 100n 63V M K T
R 11 10K 0W 25 5%
R 35 1K5 0W 25 5%
J22 Foro
SH -
S H+
OU T -
TO1 T erm inale_OU T
Foro
OU T+
J21
VO L T+
VO L T -
T E RM C I O
TECHNOLOGY 175-210-188CE/GE
Wiring diagram power board - secondary
TECHNOLOGY 175-210-188CE/GE Wiring diagram power board +5V
2
7
1
2 D36 B AV70
11
10
T P9 T es t_Po in t
9
17V8
R 34 470K 0805 1%
1
100n 50V X7R R 30
D R+ T A+ TA SH S H+
6
14 13 EN1 2 7
1
R 16 4K7 0805 1%
U 4A CD4066BC
C12 100n 50V X7R
0 ..10 V
7
SET
U 3B LM 324D
R 59 4K7 0805 5%
R 17 4K7 0805 1%
17V8
T AR+ T AR -
Q7 BC807
FAU L T
R 53 39K 0805 1% T P1 T es t_P o in t
R 10 13K 0805 1%
70354-301
R 23 2K0 0805 1%
T P2 T es t_P o in t
R 87 3K0 0805 1%
13
1
2
C7 10n 50V X7R
11
SW
T P5 T es t_P o in t
3 +5V
14
D38 BA S 40-06
3
U 1D MC 33074D
R 88 2K0 0805 1%
C40 100n 50V X7R
1
4
12
A L LARM
U 1A MC33074D 2
VO L T+
4
CADM CAD A CAD 1 CAD 2 SW LED
1K 0805 5%
T P4 T es t_P o in t
5
11
PO T -IN VCH ECK
R 27 1K 0805 5%
+5V
C16
J3 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
C10 100n 50V X7R
2 D22 BA S 40-04
U 7D 40106
R 29 10K 0805 5%
17V8 4
U 4B CD4066BC +5V
C13 100n 50V X7R
8
U 7E 40106
1 +5V
T P8 T es t_Po in t 3
D28 B A S 40-04
5 EN1 3
R 33 4K 7 0805 1%
3
+5V C22 220n 50V X7R
C20 100n 50V X7R
4
U 7A 40106
1
11
14
3
R 57 10K 0805 5%
2
R 55 1K 0805 5%
+5V
CO R TO
S T AR T
T P7 T es t_P o in t
U 7F 40106
R 49 100K 0805 5%
6 EN1 9
R 38 VR E F
4K7 0805 1%
3
12 EN1 10
R 36
2 D 29 B A S 40 -04
4K 7 0805 1% R 35 470K 0805 1%
C15 100n 50V X7R
U 3C LM 324D
OVE R S E T
0 ..2 ,5 V
R 39 4K7 0805 1%
R 60 4K7 0805 5%
Q5 BC817
R 50 4K7 0805 1%
2
VR E F Q1 BC817
R 81 39R 1206 1%
R 79 39R 1206 1%
R 80 39R 1206 1%
R 82 39R 1206 1%
R 18 820R 0805 1%
VR E F
C11 100n 50V X7R
7K5 0805 1% 7
11
D11 B AV99
R 19
2 3
R 15 0R 0805
D12 24V 0W 4 5%
R 84 200R 0805 1%
5
C14 100p 50V X7R
TA -
R 46 4K 7 0805 5%
Q4 BC807
R5 10K 0805 5%
6
4
R 64 100K 0805 5%
D42 7
5 R 12 3K 3 0805 5%
1 6
R 21 NM . C8 10n 50V X7R
C9 C42 100n 50V X7R 2n2 50V COG
R 42 10K 0805 5% 11
R ID D U T
R T /C T VR E F
COM P OU T
GND
4 8
U2 UC3845AD1
17V8
R 45 1K 0805 5%
V FB IS EN
VCC
T P 13 R 83 680R 0805 1% T es t_Po in t
2
D R+
R 62 1K 0805 5%
C26 560p 50V COG
L L4148 U 1B MC33074D
R 61 6K8 0805 5%
17V8
17V8
R 63 27K 0805 5%
S T AR T
6
8
U 5B LM 339
R 14 1K 0805 5% 17V8 C17 100n 50V X7R
C6 10n 50V X7R
C4 10n 50V X 7R
VR E F
3
R 40 13K 0805 1%
SH -
5
R 25
C 24 100n 50V X 7R
R 26 10K 0805 5%
C2 1n 50V X7R
R7 1K 0805 5%
C3 10n 50V X7R
T A R+
12
CO R TO CC
D3 L L 4148
3 2
1
+5V
2
Q2 MM B F170
D2 5V 6 0W 4 5% R 52 82K 0805 5%
R 44 2K7 0805 5% T P 15 T es t_P o in t
U 5A LM 339
4
2K 2 0805 1% Q6 BC 817 R 41 3K 3 0805 1%
SW
T AR -
R3 22K 0805 5%
9
C5 NM .
SH -
+5V
R 20 4K 7 0805 1%
17V 8 R4 47K 0805 1%
T P 11 T es t_P o in t
U 1C MC33074D
BAV99 D40 1
2
R 11 1K 0805 5%
C25 100n 50V X7R
D 43 B A S 40 -04 1
2
A L LARM
3
SET
D39 L L4148
8
10
R2 4K 7 0805 5%
3
11
U 3A LM 324D
C 41 100p 50V X 7R
T P 12 T es t_Po in t
11
1
2
R8 4K 7 0805 1%
R 86 NM . .
T P 10 T es t_P o in t
4
4 3
C1 1n 50V X 7R
U 5C LM 339
Q3 MM B F170
C19 22u 25V A ll
R 22 4K 7 0805 1%
FAU L T
- 10 -
D26 L L4148
T P 16 T es t_P o in t
R 43 33K 0805 5%
VR E F 10
C18 22u 25V A ll
U 5D LM 339 13
11 3
R 28 4K 7 0805 5%
S H+
R 47 47K 0805 5%
17V8
R9 100K 0805 1%
R1 1K 0805 5%
R 48 1K 0805 5%
R ID DU T
VO L T+
R 13 8K 2 0805 1%
14
12
3
R 65 9K 1 0805 1%
9
12
D4 G L41G
VR E F
1
7
R6 3K 3 0805 5%
3
T P 14 T es t_P o in t
12
17V8
OVE R S E T
8
9
CC
17V8
R 54 47R 0805 5%
T P3 T es t_P o in t
10
R 32 3K3 0805 1%
D23 BA S 40-04
C21 100n 50V X7R
3
U 3D LM 324D
11
4K 7 0805 1%
R 24 1K 0805 5%
3
D25 BA S 40-05
2
R 51
3
14
13
U 4D CD4066BC +5V
1
T A+
12
3
1
8
U 4C CD4066BC
+5V C 23 220n 50V X 7R
R 37 1K 0805 5%
4
U 7C 40106
4
R 31 4K7 0805 1%
12
2
13
11
3
D 37 B A V 70
6
11
U 7B 40106
1
R 58 1K 0805 5%
R 56 10K 0805 5%
5
1
3
4
2
T P6 T es t_P o in t
+5V
TECHNOLOGY 175-210-188CE/GE
REPAIR GUIDE EQUIPMENT REQUIRED
4
1
3
2
6
ESSENTIAL INSTRUMENTS 1 2 3 4
Dual trace oscilloscope Static load generator Variac 0 - 300v 1500 VA Digital multimeter
cod. 802401 (*) cod. 802110 (*) cod. 802402 (*)
USEFUL INSTRUMENTS 5 Unsoldering station 6 Miscellaneous tools
(*)The instruments with codes can be supplied by Telwin. The sale price is available on request.
- 11 -
5
TECHNOLOGY 175-210-188CE/GE TROUBLESHOOTING AND REMEDIES 1.0 Disassembling the machine Every operation should be carried out in complete safety with the power supply cable disconnected from the mains outlet and should only by done by expert or skilled electrical-mechanical personnel. - remove the current adjustment knob on the front panel of the machine (fig. 1); - undo the 4 screws attaching the handle to the top cover (fig. 1). - undo the 8 screws fastening the back and front plastic panels; 4 for the cap (fig. 1). - undo the 2 screws attaching the top cover to the base: 1 screw on each side (fig. 1). - undo the 2 screws fastening the top cover to the metal structure. - slide out the top cover upwards 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.
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 CONTACT WITH LIVE PARTS.
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. 2A) 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. Power board (figs. 2A and 2B): - rheofores of IGBT's Q6, Q7, Q8, Q9; - rheofores of recirculating diodes D37, D38; - rheofores of secondary power diodes D46, D47, D48, D49, D51; - thermostat ST2 on power transformer; - thermostat ST1 on secondary diode dissipator; - control board.
GENERAL REPAIR INSTRUCTIONS 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 300°C 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.
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: Main power supply switch (fig. 2A) Use the multimeter to check whether the contacts are stuck together or open. Probable cause: - mechanical or electric shock (e.g. bridge rectifier or IGBT in short circuit, handling under load). Current potentiometer R49 (fig. 3) Probable cause: - mechanical shock. Relay K1, K2 (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 C27,C29, C30, C31 (fig. 3) Probable cause: - mechanical shock; - machine connected to power supply voltage much higher than the rated value; - 12 -
TECHNOLOGY 175-210-188CE/GE -
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 Q6, Q7, Q8, Q9 (fig. 4) 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 D37, D38 (fig. 4) Probable cause: - excessive overheating related to faulty operation. Secondary diodes D46, D47, D48, D49, D51 (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. Power transformer and filter reactance (fig. 2A) 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.
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) Set up the oscilloscope with the voltage probe x10 connected between pin 2 (DRAIN) of Q4 and the earth on the case of U5 (fig. 3). B) Set up the multimeter in DC mode and connect the prods to the OUT+ and OUT- bump contacts. C) Position the potentiometer R49 on maximum (turn clockwise as far as it will go). D) Position the switch SW1 in MMA. E) Connect the power supply cable to a single-phase variac with variable output 0-300 Vac. 6.2 Tests for the TECHNOLOGY 175 -210-188CE/GE A) Switch on the variac (initially set to the value 0 V), switch off the main switch on the power source and increase the variac voltage gradually to 230 Vac and make sure: - the green power supply LED D43 lights up (fig. 3), - the fan for the power transformer starts up correctly, - the pre-charge relay K1 commutes (fig. 3), - the unloads relay K2 commutes (fig. 3), - for voltages close to the rated power supply value (230Vac ±15%) the power source is not in alarm status (yellow LED D39 off). NB. if the power source stays in alarm status permanently, there could be a fault in the control board (in any case, proceed to make the other tests) B) Make sure the waveform shown on the oscilloscope resembles Fig. A.
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.
FIGURA A
5.0 Electrical measurements with the machine switched off
SETTINGS: - PROBE x10; - 5V/Div; - 5µsec/Div.
A) With the multimeter set in diode testing mode check the following components (junction voltages not less than 0.2V): - rectifier bridge D31, D32 (fig. 3); - IGBT's Q6, Q7, Q8, Q9 (absence of short circuits between collector-gate and between emitter-collector fig. 4); - secondary board diodes D46, D47, D48, D49, D51 between anode and cathode (fig. 4). The secondary diodes can be checked without removing the power board: with one prod on the secondary board dissipator diodes and the other in sequence on the two power transformer outlets; - MOSFET Q4 (absence of short circuits between drain-gate and drain-source (fig. 4). B) With the multimeter set in ohm mode check the following components: - resistor R1: 47ohm (pre-charge fig. 3); - resistor R14: 3.3ohm (unloads fig. 3); - resistors R44, R45: 22ohm (primar y snubber fig. 3); - resistor R41: 10ohm (secondary snubber fig. 3); - thermostat continuity test on the power transformer: clean the resin from the bump contacts of ST2 (J2) and measure the resistance between the two bump contacts, it should be approx. 0 ohm (fig. 2B).
VERIFY THAT: - FREQUENCY IS 52KHz ±10%; - AMPLITUD IS 22V ±10%.
N.B. if no signal is present, it may be necessary to replace the MOSFET Q4 (fig. 3). C) With the multimeter set in volt mode make sure that (fig. 3): - voltage between the negative of diode bridge D31 (-) and the catode D11 (-) is equal to +40V ±10%; - voltage between the negative of diode bridge D31 (-) and the pin 3 of Q2 (+) is equal to +17.8V ±5%; - voltage between the negative of diode bridge D31 (-) and the pin 3 of U5 (+) is equal to +5V ±5%; - voltage between the pads V1- and V1+ is equal to +14V ±5% ; - voltage between the pads V2- and V2+ is equal to +14V ±5%; D) Set up the dual trace oscilloscope. Connect the probe CH1(x100) to the Q8 collector and probe CH2 (x10) to the
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 - 13 -
TECHNOLOGY 175-210-188CE/GE 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.
gate, also of Q8. The earth connections are both made to the emitter of Q8. E) Make sure the waveform displayed on the oscilloscope resembles fig. B. FIGURA B SETTINGS: - PROBE CH1 x100; - 100 V/Div; - PROBE CH2 x10; - 10V/Div; - 5µsec/Div.
7.1 Removing the power board (fig. 2A) If the fault is in the power board remove it from the bottom as follows: - 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 ( fig. 1); - remove any bands constraining the board (e.g. on the power supply cable and connections to primary); - undo the 3 screws fastening the board to the bottom (fig. 2B); - remove the board from the metal structure, lifting it upwards. N.B. for assembly proceed in the reverse order and remember to insert the toothed washer on the earth screw.
TIME TOLLERANCES ±20%. VERIFY THAT: - AMPLITUDE ON CH1 IS 320V ±10%; - POSITIVE AMPLITUDE ON CH2 IS +19V ±10%; - NEGATIVE AMPLITUDE ON CH2 IS -2V ±10%.
F) Repeat this test also for Q6, Q7, Q9 (for Q6 and Q7 use the differential probe). N.B. if the signal is not present there could be a fault in the IGBT driver circuit (fig. 3) or in the control board (fig. 2A, in this case we recommend replacing the board). G) Set the two-channel oscilloscope ready. Connect the probe CH1 (x100) on the collector of Q8 and the mass on the sender of the same Q8 probe CH2 (x10) on the pin 9 of strip J11. The masses are to be connected together on the sender of Q1. Connect the probe CH2 on the pin 5 of J7 and the mass on pin 6 of the same J7. N.B. In case you wish to measure the two wave shapes together as indicated in the figure it is necessary to use the differential probe (1/20). H) Make sure the waveform displayed on the oscilloscope resembles fig. C and that the output voltage over OUT+ and OUT - is equal to +100Vdc±10%. FIGURA C
A) Please read the procedure for replacing the IGBT's carefully: (fig. 4). The 4 IGBT's are attached to 2 different dissipators and whenever a replacement is required, both IGBT's should be all replaced. - undo the screws attaching the dissipator to the board to replace Q6, Q7 (fig. 2B); - undo the screws attaching the dissipator to the board to replace Q8, Q9 (fig. 2B); - remove the 4 IGBT's and the 2 diodes D37, D38 by unsoldering the rheofores and then clean the solder from the printed circuit bump contacts; - remove the 2 dissipators from the board; - undo the screws locking the 4 IGBT's. 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 short circuit on the PCB between the 1 st and 3rd bump contacts (between gate and emitter) corresponding to each component; - alternatively, resistors R42, R43, R46 and R47 could have burst and/or diodes D21, D22, D23 and D24 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.- Insert the new IGBT's between the dissipator and the spring, taking care not to damage the component during assembly (the spring should be inserted under pressure on the dissipator so as to lock the component); - place the dissipators with the new IGBT's and primary diodes D37 and D38 (WARNING! Make sure there is insulation between the case of diode D38 and the dissipator) in the PCB bump contacts, placing 4 spacers between the dissipator and the PCB (2 for each dissipator) and fasten them down with the screws (torque wrench setting for screws 1 Nm ±20%);
SETTINGS: - PROBE CH1 x100 - 100V/Div; - P R O B E C H 2 DIFFERENTIAL PROBE (1/20); - 100mV/Div; - 5µsec/Div. TIME TOLLERANCES ±20%. VERIFY THAT: - AMPLITUDE ON CH1 IS 320V ±10%; - P O S I T I V E AMPLITUDE ON CH2 50mV ±10%. - N E G A T I V E AMPLITUDE ON CH2 -150mV ±10%
I) Switch the power source on again and make sure that, following the brief start up time, the machine is not in alarm status (the yellow alarm LED D39 is off, fig. 3). N.B. If the machine remains in alarm status (and this is not due to a fault in the control board) there could be a fault R9 or D7 (fig. 3).
7.0 Repairs, replacing the boards 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). - 14 -
TECHNOLOGY 175-210-188CE/GE -
(1/20), on the pin 5 of J7 (control card) and the mass on pin 6 of the same strip J7. C) Set up the multimeter in DC mode and connect the prods to the OUT+ and OUT- bump contacts. D) Connect the power supply cable to the 230Vac power supply. WARNING! During tests the operator must avoid contact with the metal parts of the torch because of the presence of dangerous, high voltage.
solder the terminals taking care not to let the solder run along them; on the welding side cut away the protruding part of the rheofores and check they are not shorted (between the gate and emitter in particular).
B) Please read the procedure for replacing the secondary board diodes carefully (fig. 4): The SECONDARY DIODES are attached to the same dissipator, and when a replacement is required, all of them should be replaced: - undo the screws attaching the dissipator to the board, to replace diodes D46, D47, D48, D49 and D51; - remove the secondary diodes unsoldering the rheofores and cleaning any solder from the bump contacts on the board; - remove the dissipator from the board; - remove the spring locking the diodes; - clean any irregularity or dirt from the dissipator. If the diodes have burst the dissipator may have been irreversibly damaged: in this case it should be replaced; - apply thermo-conductive grease following the general instructions; - insert the new diodes between the dissipator and the spring, taking care not to damage the component during assembly (the screw should be inserted under pressure on the dissipator so as to lock the component); - place the dissipator with the new components in the PCB bump contacts and fasten them down with the screws (torque wrench setting for screws 1 Nm ±20%); - solder the terminals taking care not to let the solder run along them; - on the soldering side cut away the protruding part of the rheofores and check they are not shorted (between cathode and anode); N.B. make sure resistor R41 and capacitor C32 on the snubber have been soldered to the PCB correctly (fig. 3).
1.2 Tests for the TECHNOLOGY 175-210-188CE/GE A) Minimum load test: - set up the static load generator with the switch settings as in the table in Fig. D; - on the front panel position the current potentiometer at (approx.) half way. - switch on the main switch; - activate the statico load generator and make sure that: - the waveforms displayed on the oscilloscope resemble those in Fig. D; - the output current is +6Adc±20%, and the output voltage is +20.2Vdc±20%. - deactivate the static load generator and switch off the main switch.
FIGURA D SETTINGS: - PROBE CH1 x100 - 100V/Div; - PROBE CH2 differential probe (1/20) - 100mV/Div. - 5 µsec/Div. TIME TOLLERANCES ±20%. VERIFY THAT: - AMPLITUDE ON CH1 IS 320V ±10%. - AMPLITUDE ON Ch2 IS 60mV ±10%.
C) Please read the procedure for replacing the control board (fig. 3): Whatever fault occurs in the control board, we strongly recommend its replacement without attempts at repair. To remove it, cut and then unsolder from the power board the connector keeping it fixed perpendicular to the PCB, replace it and re-solder the connector.
1 2 3 4 5 6 1 0 0 0 0 0
TESTING THE MACHINE
Switch number Position number
B) Intermediate load test: - set up the ohmic load with the switch settings as in the table in fig. E; - on the front panel turn the current potentiometer to 60A (approx. half-way); - start up the ohmic load and make sure that: - the waveforms displayed on the oscilloscope resemble those in Fig. E; - the output current is equal to +60Adc ±10% and the output voltage is equal to +22.4Vdc ±10%. - switch off the ohmic load.
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 power source to the static load generator using cables fitted with the appropriate dinse connectors (code 802110). B) Set the two channel oscilloscope by connecting the probe CH1 (x100) on the collector of Q8 and the mass on the sender of the same Q8. Connect the probe CH2, of differential type - 15 -
TECHNOLOGY 175-210-188CE/GE FIGURA E
SETTINGS: - PROBE CH1 x100 - 100V/Div; - PROBE CH2 differential probe (1/20); - 100mV/Div; - 5 µsec/Div.
using trimmer R48 (fig. 3). switch off the ohmic load.
FIGURA G SETTINGS: - PROBE CH1 x100 - 100V/Div; - PROBE CH2 differential probe (1/20); - 200mV/Div; - 5µsec/Div.
TIME TOLLERANCES ±20%. VERIFY THAT: - AMPLITUDE ON CH1 IS 320V ±10%. - AMPLITUDE ON CH2 IS 120mV ±10%.
TIME TOLLERANCES ±20%. VERIFY THAT: - AMPLITUDE ON CH1 IS 320V ±10%; - AMPLITUDE ON CH2 IS 200mV ±10%.
1 2 3 4 5 6 2 2 2 1 1 1
Switch number Position number
C) Rated load test for TECHNOLOGY 175: - set up the ohmic load with the switch settings as in the table in fig. F; - 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 that: - the waveforms displayed on the oscilloscope resemble those in fig. F; - the output current is equal to +160Adc ±5% and the output voltage is equal to +26.4Vdc ±5%; if the output current reading is not 160A ±5%, adjust the current using trimmer R48 (fig. 3). - switch off the ohmic load.
1 2 3 4 5 6 3 3 3 3 3 2
Switch number Position number
E) Rated load test for TECHNOLOGY 188CE/GE: - set up the ohmic load with the switch settings as in the table in fig. H; - 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 that: - the waveforms displayed on the oscilloscope resemble those in fig. H; - the output current is equal to +140Adc ±5% and the output voltage is equal to +25.6Vdc ±5%; if the output current reading is not 140A ±5%, adjust the current using trimmer R48 (fig. 3). - switch off the ohmic load.
FIGURA F SETTINGS: - PROBE CH1 x100 - 100V/Div; - P R O B E C H 2 differential probe (1/20) - 200mV/Div; - 5µsec/Div.
FIGURA H SETTINGS: - PROBE CH1 x100 - 100V/Div; - PROBE CH2 differential probe (1/20); - 200mV/Div; - 5V/Div; - 5µsec/Div.
TIME TOLLERANCES ±20%. VERIFY THAT: - AMPLITUDE ON CH1 IS 320V ±10%; - LAMPLITUDE ON CH2 IS 180mV ±10%.
1 2 3 4 5 6 3 3 3 3 2 2
TIME TOLLERANCES ±20%. VERIFY THAT: - AMPLITUDE ON CH1 IS 320V ±10%; - AMPLITUDE ON CH2 IS 220mV ±10%.
Switch number Position number
D) Rated load test for TECHNOLOGY 210: - set up the ohmic load with the switch settings as in the table in fig. G; - 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 that: - the waveforms displayed on the oscilloscope resemble those in fig. G; - the output current is equal to +180Adc ±5% and the output voltage is equal to +27.2Vdc ±5%; if the output current reading is not 180A ±5%, adjust the current
1 2 3 4 5 6 3 3 3 2 2 2
Switch number Position number
F) Checking the secondary diode voltages: - set up the dual trace oscilloscope, connecting probe CH1 x 100 to the anode of diode D46 and probe CH2x100 to the anode of diode D51. Earth connections are both made to the secondary dissipator; - remove the multimeter from the OUT+ and OUT- bump contacts; - 16 -
TECHNOLOGY 175-210-188CE/GE -
-
set up the static load generator with the switch settings as in the table in fig. F, G or H; on the front panel position the current potentiometer 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. I; deactivate the static load generator and switch off the main switch.
FIGURA H SETTINGS: - PROBE CH1 x100 - 50V/Div; - PROBE CH2 x100; - 50V/Div; - 5µsec/Div. TIME TOLLERANCES ±20%. VERIFY THAT: - MAX REVERSE AMPLIDUTE ON CH1 AND CH2 DOES NOT EXCEED A 250V.
G) Running time check and closing the machine With the load status as in fig. F, G or H and the current adjustment potentiometer on maximum, switch on the power source and leave it in operation until the thermostatic capsules trigger (machine in alarm status). Check the correct positioning of the internal wiring and finally re-assemble the machine. H) Welding test With the power source set up according to the instructions in the handbook make a test weld at 80A (electrode diameter 2.5 mm). Check the dynamic behaviour of the power source.
- 17 -
TECHNOLOGY 175-210-188CE/GE ILLUSTRATIONS FIG. 1 SCREWS FASTENING HANDLE
SCREWS FASTENING HANDLE
CURRENT REGULATION POTENTIOMETER POWER SUPPLY LED SCREWS FASTENING BACK PANEL
ALARM LED WELDING PROCEDURE FUNCTION SELECTOR DINSE SOCKET
SCREWS FASTENING TOP COVER
SCREWS FASTENING FRONT PANEL
FIG. 2A POWER SUPPLY INTERRUPTOR
FIG. 2B FILTER CAPACITORS DIODES BRIDGE DISSIPATOR
NUTS FASTENING METALLIC STRUCTURE
CONTROL BOARD
FAN WIRE
BUMP CONTACTS THERMOSTAT ST1 (J1,J2)
NUTS RHEOFORES FASTENING Q6, Q7 METALLIC STRUCTURE
BUMP CONTACTS FAN V1,V2
Q6, Q7 DISSIPATOR SCREWS FASTENING
Q8, Q9 DISSIPATOR SCREWS FASTENING
FAN BOTTOM
IGBT DISSIPATORS
POWER TRANSFORMER
DIODES SECONDARY DISSIPATORS
SECONDARY DISSIPATOR SCREWS FASTENING
INDUCTANCE
FIG. 3 D31, D32
FIG. 4 R14
K1, K2
R40
R41
V1, V2
U5
IGBT Q6, Q7
D7,R9 Q2 R48 J7
PRIMARY DIODE D37
R49
C29 C31
D43 C30 D39
Sw1
C32
R44
R45
Q4
St2
PRIMARY DIODE D38
R38
- 18 -
IGBT Q8, Q9
RHEOFORES
Q8, Q9
NUTS FASTENING METALLIC STRUCTURE
SECONDARY DIODES D46,D47,D48,D49,D51
TECHNOLOGY 175-210-188CE/GE ELENCO PEZZI DI RICAMBIO - LISTE PIECES DETACHEES SPARE PARTS LIST - ERSATZTEILLISTE - PIEZAS DE REPUESTO TECHNOLOGY 175-210
23 1 12
22
13
25
21 24
15 11
3
17
5
26
6
10
27
2
28
16 18
20
4
14
7
8
9
19
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;
- 19 -
TECHNOLOGY 175-210-188CE/GE REF.
1 2 3 4 5 6 7 8 9
ELENCO PEZZI DI RICAMBIO PIECES DETACHEES SPARE PARTS LIST ERSATZTEILLISTE PIEZAS DE REPUESTO
Potenziometro Potentiometre Potentiometer Potentiometer Potenciometro Resistenza Resistance Resistor Wiederstand Resistencia Condensatore Condensateur Capacitor Kondensator Capacitor Diodo Diode Diode Diode Diodo Raddrizzatore Redresseur Rectifier Gleichrichter Rectificador Resistenza Resistance Resistance Widerstand Resistencia Scheda Controllo Carte Controle Control Board Steuerungskarte Tarjeta Control Bjt Tip50 Bjt Tip50 Bjt Tip50 Bjt Tip50 Bjt Tip50 Bjt Tip122 Bjt Tip122 Bjt Tip122 Bjt Tip122 Bjt Tip122
REF.
10 11 12 13 14 15 16 17 18
ELENCO PEZZI DI RICAMBIO PIECES DETACHEES SPARE PARTS LIST ERSATZTEILLISTE PIEZAS DE REPUESTO
Rele' Relais Relais Relais Relais Interruttore Interrupteur Switch Schalter Interruptor Manopola Potenziometro Poignee Pour Potentiometre Knob For Potentiometer Potentiometergriff Malja Por Resist.electr.variable Deviatore Gareur Switch Schalter Interruptor Termostato Thermostat Thermostat Thermostat Termostato Cavo Alim. Cable Alim. Mains Cable Netzkabel Cable Alim. Ventilatore Ventilateur Fan Ventilator Ventilador Induttanza Filtro Inductance Filter Filter Inductance Filter Drossel Induccion Filtro Trasformatore Ausiliario Transformateur Auxiliaire Auxiliary Transformer Hilfstransformator Transformador Auxiliar
REF.
19 20 21 22 23 24 25 26 27
ELENCO PEZZI DI RICAMBIO PIECES DETACHEES SPARE PARTS LIST ERSATZTEILLISTE PIEZAS DE REPUESTO
Induttanza Inductance Inductance Drossel Induccion Trasformatore Potenza Transformateur Puissance Power Transformer Leistungstransformator Transformador De Potencia Frontale Partie Frontal Front Panel Geraetefront Frontal Retro Partie Arriere Back Panel Rueckseite Trasera Manico Poignee Handle Handgriff Manija Presa Dinse Prise Dix Dinse Socket Dinse Steckdose Enchufe Dinse Kit Mantello Kit Capot Cover Kit Deckel Kit Kit Panel De Cobertura Kit Fondo Kit Chassis Bottom Kit Bodenteil Kit Kit Fondo Kit Igbt + Diodo Kit Igbt + Diode Kit Igbt + Diode Kit Igbt + Diode Kit Igbt + Diodo
REF.
ELENCO PEZZI DI RICAMBIO PIECES DETACHEES SPARE PARTS LIST ERSATZTEILLISTE PIEZAS DE REPUESTO
28
Kit Scheda Completa Kit Platine Complete Complete Control Pcb Kit Komplette Steurungskarte Kit Kit Tarjeta De Controlo Completa
REF.
ELENCO PEZZI DI RICAMBIO PIECES DETACHEES SPARE PARTS LIST ERSATZTEILLISTE PIEZAS DE REPUESTO
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! - 20 -
TECHNOLOGY 175-210-188CE/GE ELENCO PEZZI DI RICAMBIO - LISTE PIECES DETACHEES SPARE PARTS LIST - ERSATZTEILLISTE - PIEZAS DE REPUESTO TECHNOLOGY 188CE/GE
23 1 12
22
13
25
21 24
15 11
3
17
5
26
6
10
27
2
28
16 18
20
4
14
7
8
9
29
19
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.
- 21 -
TECHNOLOGY 175-210-188CE/GE REF.
1 2 3 4 5 6 7 8 9
ELENCO PEZZI DI RICAMBIO PIECES DETACHEES SPARE PARTS LIST ERSATZTEILLISTE PIEZAS DE REPUESTO
Potenziometro Potentiometre Potentiometer Potentiometer Potenciometro Resistenza Resistance Resistor Wiederstand Resistencia Condensatore Condensateur Capacitor Kondensator Capacitor Diodo Diode Diode Diode Diodo Raddrizzatore Redresseur Rectifier Gleichrichter Rectificador Resistenza Resistance Resistance Widerstand Resistencia Scheda Controllo Carte Controle Control Board Steuerungskarte Tarjeta Control Bjt Tip50 Bjt Tip50 Bjt Tip50 Bjt Tip50 Bjt Tip50 Bjt Tip122 Bjt Tip122 Bjt Tip122 Bjt Tip122 Bjt Tip122
REF.
10 11 12 13 14 15 16 17 18
ELENCO PEZZI DI RICAMBIO PIECES DETACHEES SPARE PARTS LIST ERSATZTEILLISTE PIEZAS DE REPUESTO
Rele' Relais Relais Relais Relais Interruttore Interrupteur Switch Schalter Interruptor Manopola Potenziometro Poignee Pour Potentiometre Knob For Potentiometer Potentiometergriff Malja Por Resist.electr.variable Deviatore Gareur Switch Schalter Interruptor Termostato Thermostat Thermostat Thermostat Termostato Cavo Alim. Cable Alim. Mains Cable Netzkabel Cable Alim. Ventilatore Ventilateur Fan Ventilator Ventilador Induttanza Filtro Inductance Filter Filter Inductance Filter Drossel Induccion Filtro Trasformatore Ausiliario Transformateur Auxiliaire Auxiliary Transformer Hilfstransformator Transformador Auxiliar
REF.
19 20 21 22 23 24 25 26 27
ELENCO PEZZI DI RICAMBIO PIECES DETACHEES SPARE PARTS LIST ERSATZTEILLISTE PIEZAS DE REPUESTO
Induttanza Inductance Inductance Drossel Induccion Trasformatore Potenza Transformateur Puissance Power Transformer Leistungstransformator Transformador De Potencia Frontale Partie Frontal Front Panel Geraetefront Frontal Retro Partie Arriere Back Panel Rueckseite Trasera Manico Poignee Handle Handgriff Manija Presa Dinse Prise Dix Dinse Socket Dinse Steckdose Enchufe Dinse Kit Mantello Kit Capot Cover Kit Deckel Kit Kit Panel De Cobertura Kit Fondo Kit Chassis Bottom Kit Bodenteil Kit Kit Fondo Kit Igbt + Diodo Kit Igbt + Diode Kit Igbt + Diode Kit Igbt + Diode Kit Igbt + Diodo
REF.
28 29
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
Kit Scheda Completa Kit Platine Complete Complete Control Pcb Kit Komplette Steurungskarte Kit Kit Tarjeta De Controlo Completa Induttanza Filtro Ge Inductance Filter Ge Ge Filter Inductance Ge Filter Drossel Induccion Filtro Ge
Scheda tecnica di riparazione: Con lo scopo di migliorare il servizio, alla fine di ogni riparazione chiediamo ad ogni Centro Assistenza di compilare e restituire a Telwin la scheda tecnica riportata nella pagina seguente. - 22 -
TECHNOLOGY 175-210-188CE/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
Rectifier bridge Electrolytic capacitors
Component ref.
Substitution of primary power board: yes Troubles evinced during repair :
Relais In-rush limiter resistance IGBT Snubber Secondary diodes Potentiometer Others - 23 -
no
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
