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cod.

988641

TECNICA TIG 155 DC


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....................................................... 9
- Equipment required 9
- General repair instructions 10
- Troubleshooting and remedies 10
- Testing the machine 13
- Illustrations 15

SPARE PARTS LIST...............................................17

REPAIR SHEET...................................................... 19

“reparation no problem !”
INPUT PRIMARY PRE-CHARGE RECTIFIER BRIDGE FILTER CHOPPER CURRENT POWER SECONDARY INDUCTANCE SECONDARY HF TRANSFORMER
OUTPUT
EMC FILTER TRANSFORMER TRANSFORMER DIODES EMC FILTER

+
-

1 2 3 4 5 6 7 8 9 10 11

BLOCK DIAGRAM
FAN POWER SUPPLY FLY-BACK POWER DRIVER PRIMARY CURRENT ALARM LED
LED SUPPLY READER

28 27 12 13 14 18

UNDERVOLTAGE DUTY CYCLE ADDER HF RELAY HF GENERATOR


SAFEGUARD MAKER

-2-
19 15 16 34 35

TIG CYCLE
CONTROL
OVERVOLATGE GALVANIC POWERED MICROCONTROLLER SOLENOID VALVE SOLEONOID VALVE
SEFEGUARD SEPARATOR TRANSFORMER
THERMOSTAT RELAY

V
TECNICA TIG 155 DC

20 21 22 17 32 33

CURRENT AUXILIARY FUNCTION FUNCTION HF SAFEGUARD TORCH BUTTON


POTENTIOMETER POTENTIOMETER SELECTOR SELECTOR

MMA HF
2T 4T LIFT
23 24 25 26 30 31

AUXILIARY
TRANSFORMER
OPERATION AND WIRING DIAGRAMS

29
TECNICA TIG 155 DC
ANALYSIS OF THE BLOCK DIAGRAM Block 9
Inductance and Shunt
NOTE: Unless indicated otherwise, it should be assumed that Consisting of: L2
the components are assembled on the primary board. The inductance levels the output current from the secondary
board diodes making it practically direct.The shunt detects the
Block 1 current circulating in the secondary and sends a voltage signal
EMC Filter to block 16 (adder), which will process it.
Consisting of: C1, L1, C5, C6.
Prevents noise from the machine from being transmitted along Block 10
the main power line and vice versa. Secondary EMC Filter
Consisting of: C50, C51.
Block 2 Prevents noise from the power source from being transmitted
Pre-charge through the welding cables and vice versa.
Consisting of: K1, R1.
Prevents the formation of high transitory currents that could Block 11
damage the main power switch, the rectifier bridge and the HF Transformer
electrolytic capacitors. Consisting of:T5 (welding machine)
When the power source is switched on the relay K1 is de- The HF transformer boosts the signal from block 30 (hf power
energised, capacitors C2, C3, C4 are then charged by R1. source), raising the voltage impulse in the secondary at the
When the capacitors are charged the relay is energised. instant when arc strike is generated.
It also isolates the welding circuit from the primary circuit
Block 3
Rectifier bridge Block 12
Consisting of: D1. Flyback power supply
Converts the mains alternating voltage into continuous pulsed Consisting of:T1, U2.
voltage. Uses switching methods to transform and stabilise the voltage
obtained from block 4 (filter) and supplies auxiliary voltage to
Block 4 power block 13 (driver) and the control board correctly.
Filter
Consisting of: C2, C3, C4. Block 13
Converts the pulsed voltage from the rectifier bridge into Driver
continuous voltage. Consisting of: ISO2, ISO3.
Takes the signal from block 12 (flyback power supply) and,
Block 5 controlled by block 15 (duty cycle maker), makes the signal
Chopper suitable for piloting block 6 (chopper).
Consisting of: Q1, Q2.
Converts the continuous voltage from the filter into a high Block 14
frequency square wave capable of piloting the power Primary current reader and limiter
transformer. Consisting of: R37 and part of the control section.
Regulates the power according to the required welding Reads the signal from block 6 (current transformer) and scales
current/voltage. it down so it can be processed and compared in blocks 15.

Block 6 Block 15
Current transformer Duty cycle maker
Consisting of:T2. Consisting of: U2 (control board)
The C.T. is used to measure the current circulating in the power Processes the information from block 16 (adder), producing a
transformer primary and transmit the information to block 14 square wave with variable duty cycle, limiting in any case the
(primary current reader and limiter). primary current to a maximum preset value.

Block 7 Block 16
Power transformer Adder
Consisting of:T3. Consisting of: U1A, U1B (control board)
Adjusts the voltage and current to values required for the Collects the value from block 19 (shunt), producing a voltage
welding procedure. Also forms galvanic separation of the signal that is suitable for processing by block 15 (duty cycle
primary from the secondary (welding circuit from the power maker).
supply line).
Block 17
Block 8 Microcontroller
Secondary diodes Consisting of: U4 (control board)
Consisting of: D21, D22, D23 . Control logic, which manages typical timing for the TIG and
D21 converts the current circulating in the transformer to a MMA cycles. Also drastically limits power source output
single direction, preventing saturation of the nucleus. current when it detects an alarm event. In the event of an alarm
D22, D23 recirculate the inductance output current (block 9) it acts directly on block 15 (duty cycle maker) and directly
when the IGBT's are not conducting, bypassing the power changes the reference signal obtained from block 23 (current
transformer (block 7). potentiomenter).

-3-
TECNICA TIG 155 DC
Block 18 Block 27
Alarm LED Power supply LED
Consisting of: D34 Consisting of: D35.
Block 17 (microcontroller) causes it to light up in the case of: Indicates when the power source is correctly powered and
1)Triggering of thermostatic capsule on power transformer. ready for use.
2)Triggering due to undervoltage.
3)Triggering due to overvoltage. Block 28
Fan
Block 19 Consisting of:V1.
Undervoltage safeguard Powered directly by block 12 (flyback transformer) and cools
Consisting of: R36, R43, U8B (control board) the power components.
If the main supply voltage falls below the minimum allowed
value this safeguard triggers (a tolerance of approx. ±15% of Block 29
the power supply voltage is allowed: outside this range the Auxiliary transformer
safeguard triggers). Consisting of: T4, D26
Its purpose is to supply a redimensioned, rectified voltage to
Block 20 power block 30 (torch button relay).
Overvoltage safeguard
Consisting of: R36, R43, U8B (control board) Block 30
If the main supply voltage exceeds the maximum value this HF safeguard
safeguard triggers (a tolerance of approx. ±15% of the power Consisting of: K4, R54, R55
supply voltage is allowed: outside this range the safeguard The HF safeguard also separates the control board from the
triggers). high frequency so as to prevent the residual signal from the
torch button cables from entering the board.
Block 21
Galvanic separation Block 31
Consisting of: ISO4 Torch button
The signal arriving from blocks 19 and 20 (over- and under- Consisting of: TIG Torch
voltage safeguard) is separated galvanically and sent to block When the torch button is operated, a separate signal is sent to
22 (power transformer thermostat) for detection of a possible block 17 (microcontroller), to achieve arc strike and enable the
alarm event, before being sent to block 17 (microcontroller). solenoid valve.

Block 22 Block 32
Power transformer thermostat Solenoid valve relay
Consisting of: ST2. Consisting of: K2
When the temperature of the power transformer is too high, the When the torch button is pressed, block 17 (microcontroller)
thermostat sends the alarm to block 17 (microcontroller). It is activates relay K2 which supplies the mains voltage needed
reset automatically after the alarm condition has ceased. to power block 33 (solenoid valve).

Block 23 Block 33
Current potentiometer Solenoid valve
Consisting of: R39 Consisting of: Y1
Used to set the reference voltage required for block 17 Supplies an appropriate amount of the desired gas mixture
(microcontroller) so as to adjust the output current: when the to strike the arc in the torch and the quantity needed to
potentiometer knob is turned the voltage on the cursor varies operate and cool the torch itself.
and therefore the current varies from the minimum to the
maximum value.
Block 34
HF relay
Block 24 Consisting of: K3
Auxiliary potentiometer When the torch button is pressed, block 17 (microcontroller)
Consisting of: R33 activates relay K3 which supplies the mains voltage needed to
Used to set the reference voltage, required by block 17 power block 35 (HF generator). It also forms galvanic
(microcontroller) to adjust the current slope down if the power separation of the control board from the high frequency so that
source is set up for TIG, or the arc force value if the power the residual signal arriving from the welding cables is unable to
source is set up for MMA. When the potentiometer knob is enter the board.
turned the voltage on the cursor varies and therefore slope
down or arc force varies from the minimum to the maximum
value. Block 35
HF generator
Block 25 Consisting of: HF generator board
Welding mode selector Using the signal sent by block 33 (HF relay), the generator
Consisting of: SW1 produces a high frequency signal that is sufficient for
The switch is used to select the desired welding procedure: powering block 11 (HF transformer).
MMA, 2T, 4T.

Block 26
Start mode selector
Consisting of: SW2
The switch is used to select the desired starting procedure: HF,
LIFT. -4-
TECNICA TIG 155 DC
ILLUSTRATIONS
Power board

(11) (9)
FLY-BACK POWER
(3) (6) TRASFORMER TRASFORMER
RECTIFIER CURRENT
(1) BRIDGE TRASFORMER
EMC (2)
FILTER PRE-CHARGE
(21)
GALVANIC
SEPARATION CONTROL
BOARD

(23)
CURRENT
POTENTIOM.

(18)
ALARM
LED
(4) (27)
FILTER POWER
SUPPLY LED

(24)
AXILIARY
POTENTIOMETER

(9)
INDUCTANCE
& SHUNT

(5) (32,34) (12) (8) (10)


CHOPPER SOLENOID DRIVER SECONDARY SECONDAY EMC
VALVE DIODES FILTER
RALAY

-5-
TECNICA TIG 155 DC
WIRING DIAGRAMS
General wiring diagram

Wiring diagram input filter board - power supply

-6-
TECNICA TIG 155 DC
Wiring diagram power board - power/driver

Wiring diagram power board - input/output

-7-
TECNICA TIG 155 DC
Wiring diagram control board

Wiring diagram HF generator board

-8-
TECNICA TIG 155 DC

REPAIR GUIDE
EQUIPMENT REQUIRED

4 1 3 2

5 7

ESSENTIAL INSTRUMENTS
1 Dual trace oscilloscope cod. 802401 (*)
2 Static load generator cod. 802110 (*)
3 Variac 0 - 300v 1500 VA cod. 802402 (*)
4 Digital multimeter
5 Differential probe 1/200

USEFUL INSTRUMENTS
6 Unsoldering station
7 Miscellaneous tools

(*)The instruments with codes can be supplied by Telwin. The sale price is available on request.

-9-
TECNICA TIG 155 DC
TROUBLESHOOTING AND REMEDIES
1.0 Disassembling the machine
WARNING: WARNING! Every operation should be carried out in complete
BEFORE PROCEEDING WITH REPAIRS TO safety with the power supply cable disconnected from the mains
outlet:
THE MACHINE READ THE INSTRUCTION - undo the 10 screws fastening the cover to the bottom: 5
MANUAL CAREFULLY. screws on each side (fig. 1);
- slide out the cover upwards (fig. 1).
WARNING: After completing the repairs, proceed in the reverse order to re-
assemble the cover and do not forget to insert the toothed washer
EXTRAORDINARY MAINTENANCE SHOULD on the ground screw.
BE CARRIED OUT ONLY AND EXCLUSIVELY
BY EXPERT OR SKILLED ELECTRICAL- 2.0 Cleaning the inside of the machine
Using suitably dried compressed air, carefully clean the
MECHANICAL PERSONNEL. components of the power source since dirt is a danger to parts
subject to high voltages and can damage the galvanic separation
WARNING: between the primary and secondary.
To clean the electronic boards we advise decreasing the air
ANY CHECKS CARRIED OUT INSIDE THE pressure to prevent damage to the components.
MACHINE WHEN IT IS POWERED MAY It is therefore important to take special care when cleaning the
CAUSE SERIOUS ELECTRIC SHOCK DUE TO following parts
Fan (fig. 2A)
DIRECT CONTACT WITH LIVE PARTS. 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
GENERAL REPAIR INSTRUCTIONS still damage after cleaning replace the fan.
Power board (figs. 2A and 2B):
- rheofores of IGBT's Q1, Q2;
The following is a list of practical rules which must be strictly
- rheofores of recirculating diodes D14, D20;
adhered to if repairs are to be carried out correctly.
- rheofores of secondary power diodes D36, D37, D38;
A) When handling the active electronic components, the IGBT's
- thermostat ST2 on power transformer;
and Power DIODES in particular, take elementary antistatic
- photocouplers ISO2 ISO3, ISO4;
precautions (use antistatic footwear or wrist straps, antistatic
- plasma control board.
working surfaces etc.).
Parts fastened to the base (fig. 4)
B) To ensure the heat flow between the electronic components
and the dissipator, place a thin layer of thermo-conductive If the power board is removed, carefully clean the HF generator
grease (e.g. COMPOUND GREASIL MS12) between the board and the HF transformer.
contact zones.
C) The power resistors (should they require replacement) should 3.0 Visual inspection of the machine
always be soldered at least 3 mm above the board. Make sure there is no mechanical deformation, dent, or damaged
D) If silicone is removed from some points on the boards, it and/or disconnected connector.
should be re-applied. N.B. Use only non-conducting neutral or Make sure the power supply cable has not been damaged or
oximic reticulating silicones (e.g. DOW CORNING 7093). disconnected internally and that the fan works with the machine
Otherwise, silicone that is placed in contact with points at switched on. Inspect the components and cables for signs of
different potential (rheophores of IGBT's, etc.) should be left to burning or breaks that may endanger operation of the power
reticulate before the machine is tested. source. Check the following elements:
E) When the semiconductor devices are soldered the maximum Main power supply switch (fig. 2A)
temperature limits should be respected (normally 300°C for no Use the multimeter to check whether the contacts are stuck
more than 10 seconds). together or open. Probable cause:
F) It is essential to take the greatest care at each disassembly - mechanical or electric shock (e.g. bridge rectifier or IGBT in
and assembly stage for the various machine parts. short circuit, handling under load).
G) Take care to keep the small parts and other pieces that are Current potentiometer R39 and auxiliary potentiometer R33
dismantled from the machine so as to be able to position them (fig. 3)
in the reverse order when re-assembling (damaged parts Probable cause:
should never be omitted but should be replaced, referring to - mechanical shock.
the spare parts list given at the end of this manual). Mode selector switches SW1 and SW2 (fig. 3)
H) The boards (repaired when necessary) and the wiring should Probable cause:
never be modified without prior authorisation from Telwin. - mechanical shock.
I) For further information on machine specifications and Relays K1, K2, K3 (fig. 3)
operation, refer to the Instruction Manual. Probable cause:
J) WARNING! When the machine is in operation there are - see main power supply switch. N.B. If the relay contacts are
dangerously high voltages on its internal parts so do not touch stuck together or dirty, do not attempt to separate them and
the boards when the machine is live. clean them, just replace the relay.
Electrolytic capacitors C2,C3 (fig. 3)
Probable cause:
- mechanical shock;
- machine connected to power supply voltage much higher than
the rated value;
- broken rheophore on one or more capacitor: the remainder will
be overstressed and become damaged by overheating;
- ageing after a considerable number of working hours;
- 10 -
TECNICA TIG 155 DC
- overheating caused by thermostatic capsule failure. 5.0 Electrical measurements with the machine
IGBT's Q1, Q2 (fig. 4) switched off
Probable cause: A) With the multimeter set in diode testing mode check the
- discontinuation in snubber network, following components (junction voltages not less than 0.2V):
- fault in driver circuit
- rectifier bridge D1 (fig. 3);
- poorly functioning thermal contact between IGBT and
- IGBT's Q1, Q2 (absence of short circuits between collector-
dissipator (e.g. loosened attachment screws: check),
gate and between emitter-collector fig. 4);
- excessive overheating related to faulty operation.
- secondary board diodes D21, D22, D23 between anode and
Primary diodes D14, D20 (fig. 4)
cathode (fig. 4). The secondary diodes can be checked
Probable cause:
without removing the power board: with one prod on the
- excessive overheating related to faulty operation.
secondary board dissipator diodes and the other in sequence
Secondary diodes D21, D22, D23 (fig. 4)
on the two power transformer outlets;
Probable cause:
- viper U2 (absence of short circuits between pin 3 - pin 4 and
- discontinuation in snubber network;
between pin 4 pin 2, fig. 3).
- poorly functioning thermal contact between IGBT and
B) With the multimeter set in ohm mode check the following
dissipator (e.g. loosened attachment screws: check);
components:
- faulty output connection.
- resistor R1: 47ohm (pre-charge fig. 3).
Power transformer and filter reactance (fig. 2A)
- resistors R21,R27: 22ohm (primary snubber fig. 3).
Power transformer and filter inductance (fig. 2A)
- resistor R45: 10ohm (secondary snubber fig. 3).
Inspect the windings for colour changes.
- thermostat continuity test on the power transformer: clean
Probable causes: the resin from the bump contacts of ST2 and measure the
- aging after a substantial number of working hours; resistance between the two bump contacts, it should be
- excessive overheating related to faulty operation. approx. 0 ohm (fig. 2B).
Shunt (fig. 2A)
Check it for colour changes. Probable cause: 6.0 Electrical measurements with the machine in
- overheating due to loosening of the screws connecting the
shunt to the PCB.
operation
WARNING! Before proceeding with faultfinding, we should
HF transformer (fig. 2A)
remind you that during these tests the power source is powered
Inspect the windings for colour changes. Probable causes:
and therefore the operator is exposed to the danger of electric
- aging after a substantial number of working hours; shock.
- excessive overheating related to faulty operation. The tests described below can be used to check the operation of
Solenoid valve (fig. 3) the power and control parts of the power source.
Check the solenoid valve to see if it opens. Probable causes:
- the solenoid valve does not open because of a mechanical 6.1 Preparation for testing
block; do not attempt to open the valve but used compressed air to A) Do not connect the gas mixture source to the power source.
carry out thorough cleaning or replace the solenoid valve. B) Set up the oscilloscope with the voltage probe x100 connected
between the case of U2 (probe) and the anodes of diode D16
TIG Torch (earth) on the power board (fig. 3).
Maintenance status, referring to the instructions given in the C) Set up a multimeter in DC volt mode and connect the prods to
instruction manual. Condition of parts not subject to wear on the the OUT+ and OUT- bump contacts.
connecting cable between torch and power source (insulation). D) Position the current potentiometer R39 on maximum (turn
clockwise as far as it will go) and the auxiliary potentiometer
4.0 Checking the power and signal wiring R33 on minimum (anti-clockwise as far as it will go).
It is important to check that all the connections are in good E) Set switch SW1 to MMA (left as far as it will go) and switch SW2
condition and the connectors are inserted and/or attached to LIFT (right as far as it will go).
correctly. To do this, take the cables between finger and thumb (as F) From the HF generator board, disconnect the fastons coming
close as possible to the fastons or connectors) and pull outwards from the HF transformer, J3 and J4 (fig.3). WARNING! the high
gently: the cables should not come away from the fastons or frequency voltage will permanently damage any instrument
connectors. N.B. If the power cables are not tight enough this connected to the generator.
could cause dangerous overheating. Before proceeding make very sure that the fastons listed above
In particular, on the power board (fig. 2A) it is necessary to check
are disconnected and completely isolated from one another.
the power wiring:
G) Connect the power supply cable to a single phase variac with
- the connection of the power supply cable to the fastons at the
main switch and to the earth faston (J3) on the power board; variable output 0-300 Vac.
- the connections from the power board to the main switch (J1, WARNING! during testing prevent contact with the metal part of
J2); the torch because of the presence of high voltages that are
- the connections to the solenoid valve (J11, J12); hazardous to the operator.
- connections to the HF generator board (J13, J14);
- connections from the torch button to the power board 6.2 Tests for the TECNICA PLASMA 31
(PT1,PT2); A) Switch on the variac (initially set to the value 0 V), switch off the
- connection from the shunt to the HF transformer; main switch on the power source and increase the variac voltage
- connections from the HF generator board (J3, J4) to the HF gradually to 230 Vac and make sure:
transformer (A, B); - the green power supply LED D35 lights up (fig. 3);
- connections of the thermostat on the power transformer (ST2); - the fan for the power transformer starts up correctly;
- fan connections (V1+, V1-); - the pre-charge relay K1 commutes (fig. 3);
- for voltages close to the rated power supply value (230Vac
- connection of the remote control wiring to the board and to the
±15%) the power source is not in alarm status (yellow LED D34
connector on the back of the machine.
off). N.B. if the power source stays in alarm status
Other checks: permanently, there could be a fault in the plasma control board
Make sure that the connections to the (out+) and (out-) dinse (in any case, proceed to make the other tests).
sockets are attached correctly to the power board.
- 11 -
TECNICA TIG 155 DC
B) Make sure the waveform shown on the oscilloscope FIGURE C
resembles fig. A.
SETTINGS:
· PROBE CH1 x10
FIGURE A · 500mV/Div;
· 5 µsec/Div.

SETTINGS CH1:
· PROBE x100; VERIFY THAT:
· 100 V/Div; · AMPLITUDE IS
· 10 µsec/Div. 500mV ±10%.

VERIFY THAT
· THE FREQUENCY
IS: 60KHz ±10%.
· AMPLITUDE IS:
450V ±10%.

I) Switch the power source off and on again and make sure that,
after the transitory switch-on time, there is no alarm (yellow
alarm LED D34 is off fig. 3).
N.B. If an alarm persists (and is not caused by a fault in the control
board) there could be a fault in opto-isolator ISO4 (fig. 3).
N.B. if no signal is present, it may be necessary to replace the
integrated circuit U2 (fig. 3).
C) With the multimeter set in volt mode make sure that(fig. 3):
- the voltage over pin 2 of U2 (+) and the anode of diode D16 (-)
7.0 Repairs, replacing the boards
If repairing the board is complicated or impossible, it should be
is equal to +13Vdc ±5%; completely replaced.
- the voltage over pads V1+ and V1- is equal to +12Vdc ±5%; The board is identified by a 6-digit code (printed in white on the
- the voltage over the ends of capacitor C10 is equal to +28V component side after the initials TW). This is the reference code
±5%; for requesting a replacement: Telwin may supply boards that are
- the voltage over the ends of capacitor C13 is equal to +28V compatible but with different codes.
±5%. WARNING! before inserting a new board check it carefully for
- the voltage over pin 1 and pin 2 of U6 is equal to +15V ±5%; damage that may have occurred in transit. When we supply a
- the voltage over pin 3 and pin 2 of U6 is equal to +5V ±5%; board it has already been tested and so if the fault is still present
D) Set up the dual trace oscilloscope. Connect the probe after it has been replaced correctly, check the other machine
CH1(x100) to the Q1 collector and probe CH2(x10) to the gate, components. Unless specifically required by the procedure, never
also of Q1. The earth connections are both made to the emitter alter the board trimmers.
of Q1.
E) Make sure the waveforms displayed on the oscilloscope 7.1 Removing the power board (fig. 2A)
If the fault is in the power board remove it from the bottom as
resemble those in fig. B;
follows:
- with the machine disconnected from the main supply,
FIGURE B disconnect all the wiring connected to the board;
- remove the two adjustment knobs on the front panel of the
SETTINGS: machine (fig. 1);
· PROBE CH1 x100; - disconnect connector J8 (remote control) and fastons PT1 and
· 100 V/Div;
· PROBE CH2 x10;
PT2 (torch button).
· 10V/Div; - cut any bands restricting the board (e.g. on the power supply
· 5 µsec/Div. cable and primary connections);
- on the soldering side, undo the two screws fastening the dinse
VERIFY THAT connectors to the PCB (fig. 2B);
· THE FREQUENCY IS - undo the 2 screws attaching the board to the base (fig. 2B).
60KHz ±10%;
· AMPLITUDE CH1 IS
- undo the two screws fastening the board to the inside of the
300V ±10%; front and back panel (fig. 2B);
· POSITIVE AMPLITUDE - after removing the screws, lift the board upwards to remove it
CH2 IS +15V ±10%; from the bottom of the machine.
· NEGATIVE AMPLITUDE
CH2 IS -10V ±10%. N.B. to re-assemble, proceed in the reverse order, remembering
to insert the toothed washers on the earth screws.

A) Please read the procedure for replacing the IGBT's


carefully (fig. 4)
F) Repeat this test on Q2 as well using the differential probe. The 2 IGBT's are attached to 2 different dissipators and whenever
a replacement is required, both IGBT's should be replaced.
N.B. if the signal is not present, there may be a fault in the IGBT - undo the screws attaching the dissipator to the board to
driver circuit (fig. 4) or the control board (fig. 3, in the latter replace Q1.(fig. 2B);
case, we recommend replacing the board). - undo the screws attaching the dissipator to the board to
G) Set up the single trace oscilloscope, connecting probe CH1 replace Q2 (fig. 2B);
(x10) to pin 6 on J9 and the earth to the case of U6. - remove the 2 IGBT's Q1,Q2 and the 2 diodes D20, D14 by
H) Make sure the waveform displayed on the oscilloscope unsoldering the rheofores and then clean the solder from the
resembles fig.C and that the output voltage over OUT+ and printed circuit bump contacts;
OUT- is equal to +91Vdc ±10%. - remove the 2 dissipators from the board;
- undo the screws locking the 2 IGBT's.
- 12 -
TECNICA TIG 155 DC
Before making the replacement make sure the components TESTING THE MACHINE
piloting the IGBT's are not also damaged:
- with the multimeter set in ohm mode make sure there is no Tests should be carried out on the assembled machine before
st rd
short circuit on the PCB between the 1 and 3 bump contacts closing it with the top cover. During tests with the machine in
(between gate and emitter) corresponding to each operation never commute the selectors or activate the ohmic
component; load contactor.
- alternatively, resistors R22 and R29 could have burst and/or WARNING! Before proceeding to test the machine, we should
diodes D12, D15, D17 and D19 may be unable to function at remind you that during these tests the power source is
the correct Zener voltage (this should have shown up in the
powered and therefore the operator is exposed to the danger
preliminary tests);
- clean any irregularity or dirt from the dissipators. If the IGBT's of electric shock.
have burst the dissipators may have been irreversibly The tests given below are used to verify power source
damaged: in this case they should be replaced; operation under load.
- apply thermo-conductive grease following the general
instructions.- Insert the new IGBT's between the dissipator 1.1 Preparation for testing
and the spring, taking care not to damage the component A) Do not connect the gas mixture source to the power source.
during assembly (the spring should be inserted under B) Connect the power source to the static load generator (code
pressure on the dissipator so as to lock the component); 802110) using cables fitted with the appropriate dinse connectors.
- place the dissipators with the new IGBT's and primary diodes C) Set up the dual trace oscilloscope, connecting probe CH1
D14 and D20 (WARNING! Make sure there is insulation (x100) to the collector on Q1 and the earth to the emitter, also on
between the case of diode D20 and the dissipator) in the PCB Q1, probe CH2 (x10) to pin 6 on strip J9 (control board) and the
bump contacts, placing 4 spacers between the dissipator and earth to the case of U6. WARNING! for the load tests it is
the PCB (2 for each dissipator) and fasten them down with the necessary to use a differential probe to prevent damage to the
screws (torque wrench setting for screws 1 Nm ±20%); oscilloscope; Probe CH1 x10 to pin 6 on strip J9 (control board)
- solder the terminals taking care not to let the solder run along and the earth to the case of U6.
them; D) Set up a multimeter in DC volt mode and connect the prods to
- on the welding side cut away the protruding part of the the OUT+ and OUT- bump contacts.
rheofores and check they are not shorted (between the gate E) Position the auxiliary potentiometer R33 to minimum (anti-
and emitter in particular). clockwise as far as it will go).
F) Set switch SW1 to MMA (left as far as it will go) and switch
B) Please read the procedure for replacing the secondary SW2 to LIFT (right as far as it will go).
board diodes carefully (fig. 4) G) From the HF generator board disconnect the fastons coming
The 3 SECONDARY DIODES are attached to the same from the HF transformer, J3 and J4 (fig.3). WARNING! the high
dissipator, and when a replacement is required, all of them should frequency voltage will permanently damage any instrument
be replaced: connected to the generator. Before proceeding make very sure
- undo the screws attaching the dissipator to the board, to that the fastons listed above are disconnected and completely
replace diodes D21, D22 and D23; isolated from one another.
- remove the 3 secondary diodes unsoldering the rheofores and H) Connect the power supply cable to the 230Vac power supply.
cleaning any solder from the bump contacts on the board; WARNING! During tests the operator must avoid contact with
- remove the dissipator from the board; the metal parts of the torch because of the presence of
- remove the spring locking the 3 diodes; dangerous, high voltage.
- clean any irregularity or dirt from the dissipator. If the diodes
have burst the dissipator may have been irreversibly 1.2 Scheduled tests
damaged: in this case it should be replaced; A)Intermediate load test:
- apply thermo-conductive grease following the general - set up the ohmic load with the switch settings as in the table in
instructions; fig. D;
- insert the new diodes between the dissipator and the spring, - on the front panel position the current potentiometer R39 at
taking care not to damage the component during assembly (approx.) half way and switch on the main switch;
(the screw should be inserted under pressure on the dissipator - start up the ohmic load and make sure that:
so as to lock the component); - the waveforms displayed on the oscillscope resemble those
- place the dissipator with the new components in the PCB in Fig. D;
bump contacts and fasten them down with the screws (torque - the output current is equal to +60Adc ±10% and the output
wrench setting for screws 1 Nm ±20%); voltage is equal to +22.4.Vdc ±10%.
- solder the terminals taking care not to let the solder run along - switch off the ohmic load and switch off the main switch.
them;
- on the soldering side cut away the protruding part of the FIGURE D
rheofores and check they are not shorted (between cathode
and anode). SETTINGS:
N.B. make sure resistor R45 and capacitor C45 on the snubber · Differential probe on CH2
1/200;
have been soldered to the PCB correctly (fig. 3). · 100V/Div = 500Mv;
· PROBE CH1 x10;
C) Please take careful note of the procedure for replacing · 2V/Div;
· 5 sec/Div.
the control board (fig. 3)
Whatever fault occurs in the control board, we strongly VERIFY THAT:
recommend its replacement without attempts at repair. · THE FREQUENCY IS
60KHz ±10%;
To remove it, cut and then unsolder from the power board the · THE AMPLITUDE ON
connector keeping it fixed perpendicular to the PCB, replace it and CH2 IS 350V ±10%;
re-solder the connector. · THE AMPLITUDE ON
CH1 IS 4V ±10%.

1 2 3 4 5 6 Switch number
2 2 2 2 1 0 Position of swicth

- 13 -
TECNICA TIG 155 DC
B) Rated load test: (right as far as it will go). Connect the TIG torch and press the
- set up the ohmic load with the switch settings as in the table in button to verify that relay K4 closes (fig. 4); if not check whether:
fig. E; - the voltage over the cathode (+) and the anode (-) of diode D27
- on the front panel position the current potentiometer R39 on is equal to +12Vdc ±20%; If not check the operation of the
maximum (turn clockwise as far as it will go) and switch on the auxiliary transformer T4 and of the diode bridge D26;
main switch; - with the machine switched off (not powered), the continuity of
- start up on the ohmic load and make sure that: R58 is equal to 0 Ohms;
- the waveforms displayed on the oscilloscope resemble those - with the machine switched off (not powered) the torch button is
in Fig. E; working properly.
- the output current is equal to +120Adc 5% and the output
voltage is equal to +24.8Vdc 5%. B) Checking solenoid valve operation
- switch off the ohmic load and switch off the main switch. After checking operation for point 1.3 A), press the button and
check whether:
FIGURE E
FIGURA - the solenoid valve closes (fig. 2A); if not check whether:
- the voltage over the female fastons (fig.4) is equal to 230Vac
SETTINGS: ±10%. If voltage is present this means the solenoid valve is
· Differential probe on CH2
1/200;
faulty, if not check the operation of relay K2;
· 100V/Div = 500Mv; - relay K2 closes (fig. 4); if not check whether:
· PROBE CH1 x10;
· 5V/Div;
- the voltage over pin 1 (+) and pin 25 of J9 (control board) is
· 5 sec/Div. equal to +15Vdc ±20%, otherwise replace the control board.
VERIFY THAT:
· THE FREQUENCY IS C) Checking HF generator operation
60KHz ±10%; Set switch SW1 to TIG/2T (in the centre) and switch SW2 to HF
· THE AMPLITUDE ON
CH2 IS 350V ±10%; (left as far as it will go). Now, only on the HF generator board,
· THE AMPLITUDE ON reconnect the fastons coming from the HF transformer, J3 and J4
CH1 IS 8V ±10%.
(fig.2A). WARNING! the high frequency voltage will permanently
damage any instrument connected to the generator. With the TIG
torch still connected and pressing the button check whether:
- the HF generator board starts to hum for about 2 seconds (high
1 2 3 4 5 6 Switch number frequency in torch); if not check whether:
3 3 2 2 2 2 Position of swicth
- the voltage over female fastons J6 and J5 (fig.4),
disconnected from the HF generator board, is equal to
230Vac ±10%; if voltage is present this means the HF
C) Checking the secondary diode voltages: generator board is faulty; if not check the operation of relay
- set up the dual trace oscilloscope, connecting probe CH1 x K3;
100 to the anode of diode D21 and probe CH2x100 to the - with the generator switched off (not powered), the following
anode of diode D22. Earth connections are both made to the components on the HF generator board:
secondary dissipator; - resistance of R11 is equal to 0 ohm;
- set up the ohmnic load generator with the switch settings as in - resistance of R1 is equal to 47 ohm;
the table in fig. E; - resistances of R9, R10 and R11 are equal to 6K8 ohm.
- on the front panel position current potentiometer R39 to the - relay K3 closes (fig. 4); if not check whether:
maximum (turn the knob clockwise as far as it will go) and - the voltage over pin 1 (+) and pin 26 (-) of J9 (control board) is
switch on the main switch; equal to +15Vdc ±20%; if not replace the control board.
- activate the ohmnic load, make sure that the waveforms
displayed on the oscilloscope resemble those in fig. F;
D) Running time check and closing the machine
- deactivate the ohmnic load generator and switch off the main
With the load status as in fig. E and the cutting current adjustment
switch.
potentiometer (R42) on maximum, switch on the power source
and leave it in operation until the thermostatic capsules trigger
FIGURE F (machine in alarm status). Check the correct positioning of the
internal wiring and finally re-assemble the machine.
SETTINGS:
· Differential probe CH1
x100;
E) Welding test
· 50V/Div; MMA: with the power source set up according to the instructions in
· SONDA CH2 x100;
· 50V/Div;
the handbook make a test weld with an electrode diam. 2.5 and
· 5 µsec/Div. the current setting at 80A. Monitor the dynamic behaviour of the
VERIFY THAT:
power source, checking for the presence of the Arc Force, by
· THE REVERSE operating potentiometer R33.
AMPLITUDE ON CH1 TIG: with the power source set up according to the instructions in
DOES NOT EXCEED
250V; the handbook make a test weld with a grey electrode diam. 2.4
· THE REVERSE and an argon gas bottle (gas flow at 4.5 litres/minute). Make a
AMPLITUDE ON CH2
DOES NOT EXCEED weld on iron or steel with the current set at 80A, making sure that
250V; the generator operates correctly in the various TIG functions,
making the tests with the power source set up according to the
instructions in the handbook, make a test weld with an electrode
diam. 2.5 and the current setting at 80A. Monitor the dynamic
behaviour of the power source, also checking for the presence of
1.3 Operational tests the slope down by operating potentiometer R33.
A) Checking torch button operation
Set switch SW1 to TIG/2T (in the centre) and switch SW2 to LIFT
- 14 -
TECNICA TIG 155 DC
ILLUSTRATIONS
FIG. 1

CURRENT REGULATION
POTENTIOMETER

POWER SUPPLY LED

ALARM LED

ARC FORCE OR SLOPE


POTENTIOMETER
REGULATION

DINSE SOCKET
SCREWS
TOP COVER
TORCH BUTTON
CONNECTOR
CONNECTOR TORCH GAS

FIG. 2A FIG. 2B

BUMP RHEOFORES BOARD


POWER CONTACTS BUMP RHEOFORES D14 SCREW
FAN BOARD THERMOSTAT
BOARD CONTACTS Q2 FASTENING
SCREW ST2 FAN V1 Q2 DISSIPATOR
POWER SUPPLY POWER FASTENING
INDUCTANCE SCREWS
INTERRUPTOR TRANSFORMER FASTENING

SCREWS
FASTENING
SHUNT IGBT Q2
DISSIPATOR
SCREWS
FASTENING
IGBT Q1
DISSIPATOR
SCREWS
FASTENING

SOLENOID VALVE HF
HF GENERATOR BOARD TRANSFORMATOR DINSE SOCKET
SCREW
BOARD RHEOFORES RHEOFORES RHEOFORES BOARD
FASTON FASTENING
FASTON SCREWS D21, D22, D23 Q1 D20 SCREWS
J5 E J6 J3(A) E JA(B) FASTENING FASTENING

- 15 -
TECNICA TIG 155 DC

FIG. 3 FIG. 4

R1 K1 C45, R45 U6 J8 J9
CAD CONTROL
C3 C2 D1 T1 U2 ISO4 BOARD FEMALE FASTONS IGBT TRASF. SECONDART DIODES
PROMARY
FOR CONNECTION DIODE Q2 T4 D21,D22,D23
R39 SOLENOID VALVE D14

Sw1

R21 D35

D34

Sw2
R27

R33

DIODO IGBT RELE’ RELE’ RELE’ SHUNT


PRIMARIO Q1 K3 K2 K4 R3
PRIMARY C10, C13 SECONDARY D16 D20
DISSIPATORS DISSIPATORS
FEMALE FASTONS J5 E J6
FOR CONNECTION
HF GENERATOR BOARD

FIG. 5

R1 R9 R10 R12

J4 (B)

J6 J5 R11 J3 (A)

- 16 -
TECNICA TIG 155 DC

ELENCO PEZZI DI RICAMBIO - LISTE PIECES DETACHEES


SPARE PARTS LIST - ERSATZTEILLISTE - PIEZAS DE REPUESTO
Esploso macchina, Dessin appareil, Machine drawing, Explosions Zeichnung des Geräts, Diseño seccionado maquina.

29
27
28
14

17
13

34

32
11

20 2 5 6 24 22 7 35 8

26
15 1

18
3
33
10 36
30
12

21 19 9 4 23 25 31

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

- 17 -
TECNICA TIG 155 DC
ELENCO PEZZI DI RICAMBIO ELENCO PEZZI DI RICAMBIO ELENCO PEZZI DI RICAMBIO ELENCO PEZZI DI RICAMBIO ELENCO PEZZI DI RICAMBIO
PIECES DETACHEES PIECES DETACHEES PIECES DETACHEES PIECES DETACHEES PIECES DETACHEES
REF. SPARE PARTS LIST REF. SPARE PARTS LIST REF. SPARE PARTS LIST REF. SPARE PARTS LIST REF. SPARE PARTS LIST
ERSATZTEILLISTE ERSATZTEILLISTE ERSATZTEILLISTE ERSATZTEILLISTE ERSATZTEILLISTE
PIEZAS DE REPUESTO PIEZAS DE REPUESTO PIEZAS DE REPUESTO PIEZAS DE REPUESTO PIEZAS DE REPUESTO
Potenziometro Scheda Generatore H.f. Cavo Alim. Pressacavo Kit Mantello
Potentiometre Platine Generateur H.f. Cable Alim. Presse Cable Kit Capot
1 Potentiometer 9 H.f. Generator Card 18 Mains Cable 26 Cable Bushing 34 Cover Kit
Potentiometer H.f. Generatorskarte Netzkabel Kabelhalter Deckel Kit
Potenciometro Tarjeta Generador H.f. Cable Alim. Prensa Cable Kit Panel De Cobertura
Resistenza Cablaggio Controllo Ventilatore Fibbia Per Cinghia Kit Scheda Completa
Resistance Cable De Controle Ventilateur Boucle Pour Courroie Kit Platine Complete
2 Resistor 10 Control Cable 19 Fan 27 Belt Buckle 35 Complete Pcb Kit
Wiederstand Kontrolkabel Ventilator Gurtschnalle Komplette Karte Kit
Resistencia Cable De Control Ventilador Hebilla Para Correa Tarjeta Completa Kit
Condensatore Cablaggio Presa Induttanza Filtro Aggancio Per Cinghia Kit Raccordo Entrata Gas
Condensateur Cable Prix Inductance Filter Accrochage Pour Courroie Kit Raccord Entree Gaz
3 Capacitor 11 Socket Cable 20 Filter Inductance 28 Belt Hook 36 Gas Pipe Connector Kit
Kondensator Steckdosekabel Filter Drossel Gurthaken Gaseintrittkit
Capacitor Cable Enchufe Induccion Filtro Gancho Para Correa Kit Racor Entrada Gas
Diodo Elettrovalvola Trasformatore Ausiliario Cinghia
Diode Electrovanne Transformateur Auxiliaire Courroie
4 Diode 12 Electrovalve 21 Auxiliary Transformer 29 Belt
Diode Elektroventil Hilfstransformator Gurt
Diodo Electrovalvula Transformador Auxiliar Correa
Raddrizzatore Manopola Per Potenziometro Trasformatore Potenza Raccordo Acqua
Redresseur Poignee Pour Potentiometre Transformateur Puissance Raccord Eau
5 Rectifier 13 Knob For Potentiometer 22 Power Transformer 30 Pipe Fitting
Gleichrichter Griff Fuer Potentiometer Leistungstransformator Wasseranschluss
Rectificador Manija Para Potenciometro Transformador De Potencia Racor Agua
Rele' Deviatore Induttanza Fondo
Relais Gareur Inductance Chassis
6 Relais 14 Switch 23 Inductance 31 Bottom
Relais Schalter Drossel Bodenteil
Relais Interruptor Induccion Fondo
Pwm Controller Interruttore Trasformatore Presa Dinse
Pwm Controller Interrupteur Transformateur Prise Dix
7 Pwm Controller
Pwm Controller
15 Switch
Schalter
24 Transformer
Transformator
32 Dinse Socket
Dinse Steckdose
Pwm Controller Interruptor Transformador Enchufe Dinse
Scheda Controllo Deviatore Trasformatore Hf Kit Igbt + Diodo
Carte Controle Commutateur Transformateur Hf Kit Igbt + Diode
8 Control Board
Steuerungskarte
17 Switch
Schalter
25 Hf Transformer
Hf Transformator
33 Kit Igbt + Diode
Kit Igbt + Diode
Tarjeta Control Conmutador Transformador Hf Kit Igbt + Diodo

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!

- 18 -
TECNICA TIG 155 DC

Official servicing centers


Repairing sheet
Date:
Inverter model:
Serial number:
Company:
Technician:

In which place has the inverter been used?


Building yard
Workshop
Others:

Supply:
Power supply
From mains without extension
From mains with extension m:

Mechanichal stresses the machine has undergone to


Description:

Dirty grade
Dirty inside the machine
Description:

Kind of failure Component ref.


Substitution of primary circuit board: yes no
Rectifier bridge Substitution of primary control board: yes no
Electrolytic capacitors Troubles evinced during repair :
Relais
In-rush limiter resistance
IGBT
Snubber
Secondary diodes
Potentiometer
Others
- 19 -
TELWIN S.p.A. - Via della Tecnica, 3
36030 VILLAVERLA (Vicenza) Italy ISO
Tel. +39 - 0445 - 858811
Fax +39 - 0445 - 858800 / 858801 9001
E-mail: telwin@telwin.com http://www.telwin.com CERTIFIED QUALITY SYSTEM
UNI EN ISO 9001:2000