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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

27
19

UNDERVOLTAGE
SAFEGUARD

ALARM BLOCK

16

15

18

DUTY CYCLE
MAKER

TRANSFORMER
PILOT

PRIMARY
CURRENT READER
AND LIMITER

14

DRIVER IGBT

SEPARATOR
TRANSFORMER

CURRENT
TRANSFORMER

13

CHOPPER

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

INDUCTANCE AND
SHUNT

24

29

FAN

TERTIARY SUPPLY

12

SECONDARY
DIODES

POWER
TRANSFORMER

POWER
TRANSFORMER
THERMOSTAT

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-

L1

N (L2 )

PE

S1
ON /O F F

-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+

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

+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

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

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

R 26
1K 0W 25 5%

R 25
220R 0W 25 5%

C 15
1u 63V M K T

D 16
B Y V 27 -200

D 15
10V 0W 4 5%

Q4
IR FD 110

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

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

R 34
470R 0W 25 5%

D 26
B Y V 27 -200

R 29
470R 0W 25 5%

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

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

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
. .

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

T1
1 /200 25A

F ILO T A

T R A FO _P P

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 .

H4

D46
V .T .

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

2
D49
S T T H 6003CW

D29
NM
. .

J1
IN /OU T

J2
IN /OU T

S T1
80C

D50
NM
. .
H5

R E LP

2
D51
S T T H 6003CW

L1
11uH

D30
NM
. .

R 38
180A = 210mV

C22
10n 300V M K P

so d
l er

JP 4

C21
10n 300V M K P

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
D36
B AV70

11

10

T P9
T es t_Po in t

17V8

R 34
470K 0805 1%

100n 50V X7R


R 30

D R+
T A+
TA SH S H+

14
13 EN1
2
7

R 16
4K7 0805 1%

U 4A
CD4066BC

C12
100n 50V X7R

0 ..10 V

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

C7
10n 50V X7R

11

SW

T P5
T es t_P o in t

3
+5V

14

D38
BA S 40-06

U 1D
MC 33074D

R 88
2K0 0805 1%

C40
100n 50V X7R

12

A L LARM

U 1A
MC33074D
2

VO L T+

CADM
CAD A
CAD 1
CAD 2
SW
LED

1K 0805 5%

T P4
T es t_P o in t

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

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%

+5V
C22
220n 50V X7R

C20
100n 50V X7R

U 7A
40106

11

14

R 57
10K 0805 5%

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%

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%

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%

C14
100p 50V X7R

TA -

R 46
4K 7 0805 5%

Q4
BC807

R5
10K 0805 5%

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

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

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

R 40
13K 0805 1%

SH -

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

+5V

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

2K 2 0805 1%
Q6
BC 817
R 41
3K 3 0805 1%

SW

T AR -

R3
22K 0805 5%

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

R 11
1K 0805 5%

C25
100n 50V X7R

D 43
B A S 40 -04
1

A L LARM

SET

D39
L L4148

10

R2
4K 7 0805 5%

11

U 3A
LM 324D

C 41
100p 50V X 7R

T P 12
T es t_Po in t

11

R8
4K 7 0805 1%

R 86
NM
. .

T P 10
T es t_P o in t

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

R 65
9K 1 0805 1%

12

D4
G L41G

VR E F

R6
3K 3 0805 5%

T P 14
T es t_P o in t

12

17V8

OVE R S E T

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

U 3D
LM 324D

11

4K 7 0805 1%

R 24
1K 0805 5%

D25
BA S 40-05

R 51

14

13

U 4D
CD4066BC
+5V

T A+

12

U 4C
CD4066BC

+5V
C 23
220n 50V X 7R

R 37
1K 0805 5%

U 7C
40106

R 31
4K7 0805 1%

12

13

11

D 37
B A V 70

11

U 7B
40106

R 58
1K 0805 5%

R 56
10K 0805 5%

T P6
T es t_P o in t

+5V

TECHNOLOGY 175-210-188CE/GE

REPAIR GUIDE
EQUIPMENT REQUIRED

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 -

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 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.

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;
- 5sec/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;
- 5sec/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 +100Vdc10%.
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;
- 5sec/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 +6Adc20%, and the output voltage
is +20.2Vdc20%.
- 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 sec/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 sec/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;
- 5sec/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;
- 5sec/Div.

FIGURA H
SETTINGS:
- PROBE CH1 x100
- 100V/Div;
- PROBE CH2 differential
probe (1/20);
- 200mV/Div;
- 5V/Div;
- 5sec/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;
- 5sec/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

17

26

10

27

28

16 18

20

14

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

17

26

10

27

28

16 18

20

14

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: telwin@telwin.com http://www.telwin.com

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