Telwin TECHNOLOGY 150 Operating instructions

cod. 988588
inverter
TECHNOLOGY 150-170-200-186CE GE
/
CONTENTS PAGE
OPERATION AND WIRING DIAGRAMS................ 2
REPAIR GUIDE.......................................................10
SPARE PARTS LIST...............................................20
REPAIR SHEET......................................................22
Block diagram 2
Analysis of the block diagram 3
Illustrations 5
Wiring diagrams 6
Equipment required 10
General repair instructions 11
Troubleshooting and remedies 11
Testing the machine 14
Illustrations 17
TROUBLESHOOTING
AND REPAIR MANUAL
TROUBLESHOOTING
AND REPAIR MANUAL
TROUBLESHOOTING
AND REPAIR MANUAL
TROUBLESHOOTING
AND REPAIR MANUAL
“reparation no problem !”

22
SECONDARY
DIODES
THERMOSTAT
TECHNOLOGY 150-170-200-186CE/GE
-2-
6
CURRENT
TRANSFORMER
17
POWER
TRANSFORMER
OUTPUT
10
SECONDARY
FILTER EMC
24
GALVANIC
SEPARATION
HYBRID
8
SECONDARY
DIAODES
5
CHOPPER
4
FILTER
3
PRE-CHARGE
2
RECTIFIER
BRIDGE
9
INDUCTANCE &
SHUNT
+
-
13
PRIMARY CURRENT
READER AND LIMITER
11
FLY-BACK
POWER SUPPLY
27
FAN
26
UNDERVOLTAGE
SAFEGUARD
V
t
25
OVERVOLTAGE
SAFEGUARD
V
t
15
ADDER
14
DUTY CYCLE
FORMATOR
20
SHUNT
AMPLIFIER
+|
21
MAXIMUN
CURRENT
REGULATOR
ALARM BLOCK
16 18
CURRENT
POTENTIOMETER
12
IGBT DRIVER
17
ALARM LED
SHORTCIRCUIT
DELAY
31 30
ARC FORCE
t
i
29
HOT START
t
i
19
WELDING MODE
FUNCTION
SELECTOR
TIG-LIFT
SOFT
HARD
28
SHORT CIRCUIT
DETECTOR
t
V
23
INDUCTANCE
THERMOSTAT
BLOCK DIAGRAM
OPERATION AND WIRING DIAGRAMSOPERATION AND WIRING DIAGRAMS
OPERATION AND WIRING DIAGRAMSOPERATION AND WIRING DIAGRAMS
PRIMARY
EMC FILTER
INPUT

-3-
ANALYSIS OFTHE BLOCK DIAGRAM
NOTE: Unless indicated otherwise, it should be assumed that
thecomponentsareassembledontheweldingmachine.
Consistingof:C3,R5,L1,C8,C9 .
Preventsnoisefromthemachinefrombeingtransmittedalong
themainpowerlineandviceversa.
Consistingof:Q1,Q2,Q3,Q4
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.
Consistingof:T1 .
TheC.T.isusedtomeasurethecurrentcirculatinginthepower
transformer primary and transmit the information to block 14
(primarycurrentreaderandlimiter).
Consistingof:T1.
Adjusts the voltage and current to values required for the
welding procedure. Also forms galvanic separation of the
primary from the secondary (welding circuit from the power
supplyline).
Block 1
Block 2
Block 5
Block 6
Block 7
Block 8
EMC Filter
Chopper
Current transformer
Power transformer
(primaryboard)
Consistingof:D3,D5(primaryboard).
Converts the alternating mains voltage to continuous pulsed
voltage NoD3presentonTechnology150).
Consistingof:K1,K2,R1(primaryboard).
Prevents the formation of high transient currents that could
damage the main switch, the rectifier bridge and the
electrolytic capacitors.When the power source is switched on
relaysK1andK2arede-energised,capacitorsC2,C4,C5,C6,
C7 are therefore charged via R1. When the capacitors are
charged the relay will be energised. ( No K2 present on
Technology150).
Consistingof:C2,C4,C5,C6,C7(primaryboard).
Converts the pulsed voltage arriving from the rectifier bridge
to continuous voltage ( No C7 present on Technology
150).
(primaryboard).
(primaryboard)
Consistingof:D1,D2,D3,D5(secondaryboard).
- D1and D2 convert thecurrentcirculating in thetransformer
to a single direction, preventing saturation of the nucleus.
:NoD2onTechnology150).
Rectifier bridge
Pre-charge
Filter
Secondary diodes
(N.B.
N.B.
N.B.
(N.B.
Block 3
Block 4
- D3, D5 recirculate the inductance output current (block 9)
during the time when the IGBT's are not conducting,
bypassingthepowertransformer(block7).
Consistingof:L1,R1.
The inductance levels the output current from the secondary
boarddiodesmaking it practicallydirect.The shunt detects the
currentcirculatinginthesecondaryandsendsavoltagesignal
toblock16(adder),whichwillprocessit.
Inductance and Shunt
hybridboard.
block 14 (duty
cyclemaker).
Block 9
Block 10
Block 11
Block 12
Block 13
Block 14
Block 15
Block 16
Secondary EMC Filter
Flyback power supply
IGBT Driver
Primary current reader and limiter
Duty cycle maker
Adder
Alarm Block
Consistingof: CY1,CY2.
Prevents noise from the power source from being transmitted
throughtheweldingcablesandviceversa.
Consistingof:T2,U2(primaryboard).
Uses switching methods to transform and stabilise the voltage
obtained from block 4 (filter) and supplies auxiliary voltage to
powerblock12(driver)andthe
Consistingof:U1A,U1D(primaryboard).
Takes the signal from block 11 (flyback power supply) and,
controlled by block 14 (duty cycle maker), makes the signal
suitableforpilotingblock6(chopper).
Consistingof: R15(primaryboard).
Readsthesignalfromblock6(currenttransformer)andscales
itdownso it canbeprocessed and comparedin
Consistingof:U2(hybridboard).
Processes the information from block 15 (adder) and block 13
(primary current reader and limiter) and produces a square
wave with variable duty cycle limiting the primary current to a
maximumpre-setvalueunderallcircumstances.
Consistingof:U1A,U1D(hybridboard).
Gathers all the information from block 13 (primary current
reader and limiter), from block 16 (alarms) and from block 18
(current potentiometer), and produces a signal with a suitable
voltageforprocessingbyblock14(dutycyclemaker).
Consistingof:Q5,R11,R14,R17(controlboard).
When an alarm is detected the power source output current is
drastically reduced by making direct adjustments to block 14
(duty cycle maker) and directly changing the reference signal
obtainedfromblock18(currentpotentiometer).
TECHNOLOGY 150-170-200-186CE/GE
TECHNOLOGY 150-170-200-186CE/GE

-4-
Block 25
Block 23
Block 27
Block 28
Block 29
Block 30
Block 31
Overvoltage safeguard
Undervoltage safeguard
Fan
Short circuit detector
Hot Start
Arc Force
Short circuit delay
Consistingof:U3A,R62,R68(primaryboard).
If the main supply voltage exceeds the maximum value this
safeguard triggers (a tolerance of approx. ±15% of the power
supply voltage is allowed: outside this range the safeguard
triggers).
Consistingof:U3B,R61,R67(primaryboard).
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
safeguardtriggers).
Consistingof:V1.
Powered directly 230V by block 11 (flyback transformer) and
coolsthepowercomponents.
Consisting of: U3B (hybrid board).
If the welding voltage is below 10V this circuit causes block 30
(arcforce)totrigger.
Consisting of: Q2,Q3,C9 (hybrid board).
At the start of MMA welding, Hot Start generates a temporary
overcurrent based on the current setting made by block 20
(current potentiometer) in order to pre-heat the electrode and
preparetheweldpool.
Consisting of: Q6, Q7, C14 (hybrid board).
If the arc voltage falls below 10V, this block produces a
temporary increase in the output current, so as to detach the
electrodefromthepieceafterithasbecomestuck.
Consisting of: U3B (hybrid board).
If the output shorting persists this block shuts down the
power source via block 16 (alarms).
TECHNOLOGY 150-170-200-186CE/GE
Block 17
Block 18
Block 19
Block 20
Block 21
Block 22
Block 23
Block 24
Alarm LED
Current potentiometer
Welding mode function selector
Shunt Amplifier
Maximum current regulator
Secondary diode thermostat
Inductance thermostat
Galvanic separation
Consistingof:D9(primaryboard).
Itisswitchedonbyblock16(alarms)intheeventof:
1) Triggeringofthermostaticcapsuleoninductance.
2) Triggeringofthermostaticcapsuleonsecondarydiodes.
3) Triggeringduetoundervoltage.
4) Triggeringduetoovervoltage.
5) Short circuit at output (electrode holder clamp and earth
cable connected to one another or electrode stuck to piece
beingwelded).
Consistingof:R16(primaryboard).
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
minimumtothemaximumvalue.
Consisting of: SW1 (primary board)
The switch is used to select the type of welding procedure:
TIG-Lift, Hard or Soft.
Consisting of: U4 (hybrid board)
Amplifies the signal arriving from block 10 (shunt
inductance), making it suitable for block 21 (maximum
current regulator).
Consistingof:R13(primaryboard)
Used to regulate the maximum welding current that can be
suppliedbythepowersource.
Consistingof:ST1
Whenthetemperatureofthesecondarydiodedissipatoristoo
highthethermostatcutsin,sendinganalarmsignaltoblock24
(galvanic separation).It is reset automatically when this alarm
conditionisnolongerpresent.
Consistingof:ST2
When the temperature of the inductance is too high the
thermostat cuts in, sending an alarm signal to block 24
(galvanic separation).It is reset automatically when this alarm
conditionisnolongerpresent.
Consistingof:ISO3(primaryboard).
The signals arriving from blocks 22 and 23 (transformer
thermostat and inductance thermostat) are separated
galvanically and sent to block 16 (alarms) for detection of a
possiblealarmevent.
TECHNOLOGY 150-170-200-186CE/GE

(12)
DRIVER
IGBT (5)
CHOPPER
(8)
SECONDARY DIODES
(2)
RECTIFIER
BRIDGE
(5)
CHOPPER (18)
CURRENT
POTENTIOMETER
(11)
FLY-BACK
POWER SUPPLY
(4)
FILTER
(1)
EMC
FILTER
(9)
SHUNT (10)
FILTER
SECONDARY
EMC
(8) DIODESSECONDARY
(3)
PRE-CHARGE
(17)
ALARM
LED
HYBRID BOARD
(25-26)
OVER/UNDER VOLAGE
SAFEGUARD
(22)
THERMOSTAT
SECONDARY DIODES
ILLUSTRATIONS
-5-
Primary board
Secondary board
(6)
CURRENT
TRASFORMER
(24)
GALVANIC
SEPARATION
(19)
FUNCTIONS
SELECTOR
TECHNOLOGY 150-170-200-186CE/GE
TECHNOLOGY 150-170-200-186CE/GE

General wiring diagram
-6-
WIRING DIAGRAMS
TECHNOLOGY 150-170-200-186CE/GE

-7-
Schema elettrico scheda primario - Driver
TECHNOLOGY 150-170-200-186CE/GE
TECHNOLOGY 150-170-200-186CE/GE
Wiring diagram primary board - Power

-8-
TECHNOLOGY 150-170-200-186CE/GE
Wiring diagram primary board - Power supply
Wiring diagram primary board - Driver

-9-
Wiring diagram secondary board
TECHNOLOGY 150-170-200-186CE/GE
TECHNOLOGY 150-170-200-186CE/GE
Wiring diagram hybrid board

4
38
12
9
5
76
-10-
TECHNOLOGY 150-170-200-186CE/GE
(*)The instruments with codes can be supplied by Telwin. The sale price is available on request.
REPAIR GUIDEREPAIR GUIDE
REPAIR GUIDEREPAIR GUIDE
EQUIPMENT REQUIRED
ESSENTIAL INSTRUMENTS
USEFUL INSTRUMENTS
1 Dual trace oscilloscope cod. 802401 (*)
2 Static load generator cod. 802110 (*)
3 Variac 0 - 300v 1500 VA cod. 802402 (*)
4 Digital multimeter
8 Unsoldering station
9 Miscellaneous tools
5 Differential probe 1/200
6 Hall Probe cod. 802406
cod. 802403
(*)
(*)7 HV Power supply

WARNING:
WARNING:
WARNING:
BEFORE PROCEEDING WITH REPAIRS TO
THE MACHINE READ THE INSTRUCTION
MANUALCAREFULLY.
EXTRAORDINARY MAINTENANCE SHOULD
BE CARRIED OUT ONLY AND EXCLUSIVELY
BY EXPERT OR SKILLED ELECTRICAL-
MECHANICALPERSONNEL.
ANY CHECKS CARRIED OUT INSIDE THE
MACHINEWHENITISPOWEREDMAY CAUSE
SERIOUS ELECTRIC SHOCK DUETODIRECT
CONTACTWITHLIVEPARTS.
HV POWER SUPPLY MODULE
THE HV POWER SUPPLY is used to ensure operation of the
switchingpowersupply(thecircuitontheprimaryboardsupplying
auxiliary voltages), even when the machine is operating at low
voltage.
It is easy to build using the electrical diagrams in fig. A for
reference and using the following components or, alternatively, it
canbeorderedfromTelwin.
T1=insulationtransformer230-230V 50VA(*)
D1=rectifierbridge36MB80 (cod.112357)
C1=electrolyticcapacitor470uF400VALL
(cod.112514)
R1=resistor10ohm5W5%
R2=resistor100Kohm2W5%
F1=delayedactionfuse1.5A Fuseholder5X20mm
Femaleredandblackfaston
Plasticbox.
The following is a list of practical rules which must be strictly
adheredtoifrepairsaretobecarriedoutcorrectly.
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
workingsurfacesetc.).
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
contactzones.
C) The power resistors (should they require replacement) should
alwaysbesolderedatleast3mmabovetheboard.
D) Ifsiliconeisremovedfromsomepointsontheboards,itshould
be re-applied. 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
reticulatebeforethemachineistested.
E) When the semiconductor devices are soldered the maximum
temperaturelimitsshouldberespected(normally300 Cforno
morethan10seconds).
F) It is essential to take the greatest care at each disassembly
andassemblystageforthevariousmachineparts.
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
thesparepartslistgivenattheendofthismanual).
H) The boards (repaired when necessary) and the wiring should
neverbemodifiedwithoutpriorauthorisationfromTelwin.
I) For further information on machine specifications and
operation,refertotheInstructionManual.
J) When the machine is in operation there are
dangerouslyhighvoltageson its internalpartssodonottouch
theboardswhenthemachineislive.
Every operation should be carried out in complete
safety with the power supply cable disconnected from the mains
outlet:
- Undothe8screwsfasteningthe2plasticcovers(4each) tothe
frontandback .
- Undo the 8 screws fastening the top cover to the structure
.
- Slideoutthetopcoverbypullinggentlyoutwards .
After completing the repairs, proceed in the reverse order to re-
assemble the cover and do not forget to insert the toothed washer
onthegroundscrew.
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
betweentheprimaryandsecondary.
To clean the electronic boards we advise decreasing the air
pressuretopreventdamagetothecomponents.
It is therefore important to take special care when cleaning the
followingparts
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
stilldamageaftercleaningreplacethefan.
rheoforesofIGBT'sQ1,Q2,Q3,Q4;
rheoforesofrecirculatingdiodesD4,D8;
rheoforesofsnubbernetworkdiodesD1,D6;
GENERAL REPAIR INSTRUCTIONS
TROUBLESHOOTING AND REMEDIES
N.B.
WARNING!
WARNING!
(figure1A)
(figure1B) (figure1B)
-
-
-
°
1.0 Disassembling the machine
2.0 Cleaning the inside of the machine
Fan fig. 2B
Primary board (fig. 3:)
()
-11-
10 5
F1 R1
R2
D1
T1
FIGURE A
TECHNOLOGY 150-170-200-186CE/GE
TECHNOLOGY 150-170-200-186CE/GE
ELECTRICAL DIAGRAM FOR POWER SUPPLY (HV OUTPUT):
THE INSULATION TRANSFORMER CAN BE REPLACEDWITH
TWO TRANSFORMERS OF THE SAME POWER,
CONNECTING THE SECONDARIES ACCORDING TO THE
FOLLOWINGDIAGRAM:

-
-
N.B.
-
fig.3
fig.3
WARNING!
fig.3
fig.3
fig.3
WARNING!
WARNING!
fig.3
rheoforesofopto-couplersISO1andISO2;
rheoforesofconnectorsJ4andJ6;
Do this if it is necessary to remove the primary board, otherwise it
is possible to clean the part superficially from the side of the
secondaryboard.
If the primary and secondary boards are removed (with the
diaphragm), carefully clean all the parts fastened to the base, or
cleanthebasepartiallyfromthesidesofthemachine.
Make sure there is no mechanical deformation, dent, or damaged
and/ordisconnectedconnector.
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.Checkthefollowingelements:
Probablecause:
- see main power supply switch. If the relay contacts are
stuck together or dirty, do not attempt to separate them and
cleanthem,justreplacetherelay.
Probablecause:
- mechanicalshock;
- machineconnected to powersupply voltagemuch higherthan
theratedvalue;
- brokenrheophoreononeormorecapacitor:theremainderwill
beoverstressedandbecomedamagedbyoverheating;
- ageingafteraconsiderablenumberofworkinghours;
- overheatingcausedbythermostaticcapsulefailure.
Probablecause:
- discontinuationinsnubbernetwork,
- faultindrivercircuit
- poorly functioning thermal contact between IGBT and
dissipator(e.g.loosenedattachmentscrews:check),
- excessiveoverheatingrelatedtofaultyoperation
Probablecause:
- excessiveoverheatingrelatedtofaultyoperation.
Probablecause:
-mechanicalshock.
Probablecause:
- discontinuationinsnubbernetwork;
- poorly functioning thermal contact between IGBT and
dissipator(e.g.loosenedattachmentscrews:check);
- faultyoutputconnection.
Checkitforcolourchanges.
Probablecause:
overheatingduetolooseningofthescrewsconnectingtheshunt
tothePCB.
Inspectthewindingsforcolourchanges.
Probablecauses:
- agingafterasubstantialnumberofworkinghours;
- excessiveoverheatingrelatedtofaultyoperation.
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, takethe cables betweenfinger 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.Ifthepowercablesarenottightenoughthiscould
causedangerousoverheating.
A) With the multimeter set on diode testing check the following
components(jointvoltagesnotlessthan0.2V):
- rectifierbridgesD3,D5( );
- IGBT's Q1, Q2, Q3, Q4, (no short circuits between collector-
gateandcollector-emitter( );
Beforeproceedingwithfaultfinding,weshouldremind
you that during these tests the power source is powered and
thereforetheoperatorisexposedtothedangerofelectricshock.
The tests described below can be used to check the operation of
thepowerandcontrolpartsofthepowersource.
A) From the primary board, disconnect fastons CN3 (XF+) and
CN10(XF-)forthepowertransformer( ).
B) OntheprimaryboarddisconnectthejumperonJP1.
C) Connect the HV power supply OUT (code 802403) on the
primaryboardasfollows( ):
- (+) Positive (clamp) to rheofore of resistor R35 towards JP1
(afterremovingjumperJP1);
- (-)Negative(faston)tonegativefastonofdiodebridgeD3.
D) Setuptheoscilloscopewiththevoltageprobe x100connected
between the rheofore of R40B (collector Q10) towards JP1
(probe) and the negative of diode bridge D3 (earth) to the primary
board( ).
the high frequency voltage will permanently damage
any instrument connected to the generator. Before proceeding
makeverysurethatthefastonslistedabovearedisconnectedand
completelyisolatedfromoneanother.
F) Connect the power supply cable to a single phase variac with
variableoutput0-300Vac.
during testing prevent contact with the metal part of
the torch because of the presence of high voltages that are
hazardoustotheoperator.
A) Switch on the HV power supply (HV OUT) and make sure that
():
- pre-chargerelaysK1andK2close;
- thefanstartstoturnforthepowertransformer;
Power transformer and inductance assembly
Parts fastened to the base
Relays K1,K2 primary board fig. 3
Electrolytic capacitors C2,C4,C6,C7 primary board (fig.3
IGBT's Q1, Q2, Q3, Q4 primary board (fig. 3)
Primary diodes D1, D4, D6, D8 primary board (fig. 3)
Mode selector switches SW1 and SW3 primaryboard
(fig. 3)
Secondary diodes D1, D2, D3, D5 secondary board (fig. 4)
Shunt R1 secondary board (fig. 6)
Power transformer and filter inductance
3.0 Visual inspection of the machine
4.0 Checking the power and signal wiring
5.0 Electrical measurements with the machine
switched off
6.0 Electrical measurements with the machine in
operation
()
)
.
6.1 Preparation for testing
6.2 Scheduled tests
Secondary board (fig. 4):)
-
-
-
fig.4
fig.3 fig.3
fig.4
fig.4
rheofores of secondary power diodes D1, D2, D3, D5 (N.B.not
presentonTechnology150);
thermostatST1onsecondarydiodedissipator;
shuntR1.
- secondary diodes D1, D2, D3, D5 between anode and
cathode ( ).The secondary diodes can be tested without
removingtheprimaryboard, placing aprodon thesecondary
diode dissipator and the other in sequence on the 2 power
transformeroutputterminals.
B) With the multimeter in ohm mode check the following
components:
- resistorR1:47ohm(precharge ).
- resistorsR2,R6:10ohm(primarysnubber ).
- resistorR1:10ohm(secondarysnubber ).
- thermostat continuity test on inductance and secondary
dissipator: disconnect connector J2 from the primary board
andmakesuretheresistancebetweenpins4and5isapprox.
0ohm( ).
E) Position the current potentiometer R16 on maximum (turn
clockwiseasfarasitwillgo)andswitchSW1toSOFT(asfardown
asitwillgo);
Current potentiometer R16 (fig. 3)
Probablecause:
- mechanicalshock.
-12-
TECHNOLOGY 150-170-200-186CE/GE

- yellowledalarmisturnoff.
Make sure the waveform shown on the oscilloscope
resembles .
if there is no signal it may be necessary to replace the
integratedcircuitU2orIGBTQ10ontheprimaryboard( ).
C) Set up the multimeter in volt mode and make sure the primary
boardhasthefollowingvoltages:( ):
- betweenthecathodeofdiodeD32(+)andthenegativeofdiode
bridgeD5(-):equalto+15Vdc 3%;
- between pin 3 (+) and the dissipator (-) of U4:equal to +12Vdc
5%;
- betweenpin3(+)andpin1(-)ofU6:equalto-12Vdc 5%;
- betweenpin8(+)andpin7(-)ofISO1:equalto+26Vdc 5%;
- betweenpin8(+)andpin7(-)ofISO2:equalto+26Vdc 5%;
D) SwitchofftheHVpowersupply.
E) Set up the oscilloscope with the voltage probe x10 connected
between the gate (probe) and the emitter (earth) of IGBT Q4 on
theprimaryboard ).
F) Switch on the HV power supply (HV out) and make sure the
waveformdisplayedontheoscilloscoperesembles .
G) RepeatthistestonQ1,Q2,Q3aswell.
if the signal is not present there could be a fault in the IGBT
driver circuit, specifically ISO1 and ISO2 ( ), or in the hybrid
board( ,inwhichcasewerecommendreplacingtheboard).
H) Switch off the HV and replace the 2 fastons connecting the
primaryboardandthepowertransformer(CN3andCN10).
I) Switch on the HV and the variac (initially set to 0V), close the
main power supply switch on the machine and gradually increase
thevoltagegeneratedbythevariacuntilitreaches26Vac.
J) Setuptheoscilloscopewiththevoltageprobex100connected
between the collector (probe) and the emitter (earth) of IGBT Q4
ontheprimaryboard( ).
K) Make sure the waveform shown on the oscilloscope
resembles
L) RepeatthistestonQ2aswell,usingthedifferentialprobe.
If the signal is not present there may be a fault in the IGBT's
().
M) Return the variac voltageto 0V, switchoff the machine and the
HVpowersupply.
N) Disconnect the HV power supply, replace jumper JP1 on the
board.
P) Increase the voltage on the variac to 230Vac and make sure
thealarmceases(yellowLEDD9goesoff).
Q) Increase the voltage on the variac yet again to 275Vac 5%
and make sure the machine registers an alarm again.Return the
variac voltage immediately to 230Vac and switch off the machine.
if an alarm persists (and is not caused by a fault in the hybrid
board) there could be a fault in opto-isolator ISO3 or integrated
circuitU3ontheprimaryboard( ).
If repairing the board is complicated or impossible, it should be
completelyreplaced.
The board is identified by a 6-digit code (printed in white on the
componentsideaftertheinitialsTW).Thisisthereferencecodefor
requesting a replacement: Telwin may supply boards that are
compatiblebutwithdifferentcodes.
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
altertheboardtrimmers.
If the fault is in the primary board remove it from the machine
structureasfollows:
- with the machine disconnected from the main power supply
disconnectallthewiringfromtheprimaryboard;
- cut any bands restricting the board (e.g. on the power supply
cableandprimaryconnections);
- undo the screws fastening the front and back panels and
removethepanelsfromthemachinestructure;
- undo the screws fastening the primary board to the machine
structure ;
- removetheprimaryboardbyliftingitupwards.
for assembly proceed in the reverse order.
B) Fig.B
N.B. fig.3
fig.3
(fig.3
fig.C
N.B. fig. 3
fig.3
fig.3
fig.D.
N.B.
fig.5
N.B.
fig.3
WARNING!
(fig.2B)
N.B.
7.0 Repairs, replacing the boards
7.1 Removing the primary board (fig. 3)
±
±±±
±
±
±
O) Switch the machine on again and gradually increase the
voltagegeneratedbythevariacto115Vac 5%thenmakesurean
alarmisregisteredwithyellowLEDD9litup.
- remove the current adjustment knob on the front panel of the
machine;
-13-
TECHNOLOGY 150-170-200-186CE/GE
TECHNOLOGY 150-170-200-186CE/GE
FIGURE B
SETTINGS:
· PROBE x100;
· 100 V/Div;
· 10 sec/Div.
· THE FREQUENCY
IS 35KHz ±15%;
· AMPLITUDE IS
450V ±10%;
µ
VERIFY THAT
SETTINGS:
· PROBE x10;
· 10V/Div;
· 10 sec/Div.
· POSITIVE AMPLITUDE
IS +18V ±10%;
· NEGATIVE AMPLITUDE
IS -10V ±10%.
µ
VERIFY THAT
FIGURE C
FIGURE D
SETTINGS:
· PROBE x100;
· 10V/Div;
· 10 sec/Div.
· AMPLITUDE ON
CH1 IS 35V ±20%;
µ
VERIFY THAT

Please read the procedure for replacing the IGBT's
carefully (fig. 3).
ohm
NOTE.
WARNING!
figure3
WARNING!
The4 IGBT'sareattached to2differentdissipatorsandwhenever
areplacementisrequired,bothIGBT'sshouldbereplaced.
- Unscrewthefour(4)nutsthatfixthedissipatorontothecard;
- unscrew the four (4) screws that fix the four (4) IGBT onto the
dissipator;
- unscrew the two (2) screws that fix the two diode bridges onto
thedissipator;
- remove the four (4) IGBT and the two (2) diode bridges by
unweldingthereophores,thenremovetinfromthe p r i n t e d
plates;
- removedissipatorfromcard.
Before making the replacement make sure the components
piloting the IGBT's are not also damaged:
- with the multimeter set in mode make sure there is no
shortcircuitonthe PCB between the 1 and3 bump contacts
(between gate and emitter) corresponding to each
component;
- alternatively, resistors R3, R4, R7, R8 could have burst and/or
diodes D11, D12, D15, D16 may be unable to function at the
correct Zener voltage (this should have shown up in the
preliminarytests);
- clean any irregularity or dirt from the dissipators.If the IGBT's
have burst the dissipators may have been irreversibly
damaged:inthiscasetheyshouldbereplaced;
- apply thermo-conductive grease following the general
instructions.
- prepare the components for replacement. For the IGBT's,
bend the rheofores at 90° (never bend and/or place the parts
undertensionnearthecase).
- position the components on the dissipator with the fastening
screws,butdonottightenthescrewscompletely
- join the dissipator/component assembly to the printed board,
inserting all the rheofores in the bump contacts and the
threadedspacersonthe4attachmentholes.
- attachthe dissipatorswiththe nutsand lockthemonceand for
allinthefollowingorder:
- thenutsfasteningthedissipatorsto theprintedcircuitwitha
torquewrenchsettingof2Nm±20%;
- the screws fastening the rectifiers to the dissipators with a
torquewrenchsettingof2Nm±20%;
- the screws fastening the IGBT's to the dissipators with a
torquewrenchsettingof1Nm±20%.
- solder the terminals taking care not to let the solder run along
them.
- on the component side cut away the protruding part of the
rheofores and check they are not shorted (especially the gate
andemitter).
The 4 IGBT's should belong to the same selection kit
suppliedbyTelwin.
- remove the 4 diodes by unsoldering the rheofores and also
removethesolderfromthebumpcontactsonthePCB;
- clean any irregularities or dirt from the dissipators.If the diodes
haveburstthedissipatormaybeirreparablydamaged:insucha
caseitshouldbereplaced;
- apply thermoconductive paste following the general
instructions;
- place the dissipator with the new components on the bump
contacts of the PCB and fasten it down with the screws (torque
wrenchsetting1Nm20%);
- solder the terminals taking care not to let the solder run along
them;
- on the soldering side cut the protruding part of the rheofores
and make sure they have not shorted (between cathode and
anode).
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. 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
underload.
A) Connect the machine to the static load generator (code
802110)usingcablesfittedwiththeappropriatedinseconnectors.
B) Set up the dual trace oscilloscope with the voltage probe
CH1x100connectedbetweenthecollector(probe)andtheemitter
ofQ4(earth)ontheprimaryboard( ).
C) Pass the current probe of the Hall effect transducer along the
cable connecting the power transformer at faston CN10 with the
referencearrowpointingintoCN10.
D) Lastly, connect the Hall Probe and the current probe to the
oscilloscope.
E) Set up a multimeter in DC volt mode and connect the prods to
theOUT+andOUT-dinseconnections.
F) On the front panel set switch SW1 to SOFT (as low as it will
go). the high frequency voltage will permanently damage
any instrument connected to the generator. Before proceeding
makeverysurethatthefastonslistedabovearedisconnectedand
completelyisolatedfromoneanother.
st rd
TESTING THE MACHINE
1.1 Preparation for testing
7.2 Removing the hybrid board (fig. 3)
7.3 Removing the secondary board (fig. 4)
If the fault is in the hybrid board remove it from the primary board
asfollows:
with the primary board removed from the machine structure
unsolder the rheofores from the hybrid board on the soldering
side;
removethesolderfromthebumpcontactsonthePCB;
removethehybridboardfromtheprimaryboard;
forassemblyproceedinthereverseorder.
If the fault is in the hybrid board we strongly advise replacing it
withoutfurtherintervention.
If the fault is in the secondary board, unless the dissipator has
beendamagedbyadestructiveexplosionofthediodes,theboard
does not generally need to be removed and the diodes can be
replaced directly with the board mounted on the machine.In any
case, it should be specified that to remove it, it is necessary to
separatethebasefromthemachinestructureasfollows:
- withthemachinedisconnectedfromthemainsupplyundothe4
side screws (2 on the front and 2 on the back) that attach the
boardtothebase;
- turn the machine upside down and undo the 2 screwsfastening
thebase tothestructure;
- finallyremovethebasefromthestructure.
Completeremovalofthesecondaryboardfromthestructure:
- undo the 4 side screws fastening the board to the machine
structure;
- removethe3 hexagonal-headscrewsthatfastenthe shunt and
connectthepowertransformer;
- disconnectthewiringforthethermostaticcapsule.
forassemblyproceedinthereverseorder.
The 4 secondary DIODES are attached to the dissipator and
wheneverareplacementismade,all4diodesshouldbereplaced:
make sure that resistor R1 and capacitor C1 of the snubber
aresolderedcorrectly( ).
-
-
-
N.B.
N.B.
Take special note of the procedure for replacing the
secondarydiodes:
N.B. fig.3
-14-
TECHNOLOGY 150-170-200-186CE/GE

G) Connectthepowersupplycabletothe230Vacpowersupply.
during testing prevent contact with the metal part of
the torch because of the presence of high voltages that are
hazardoustotheoperator.
Switch on the machine, gradually increase the power supply
voltagefrom0Vto230Vacandmakesurethat:
- thepre-chargerelaysontheprimaryboardclose;
- thefanstartsoperatingcorrectly;
- the waveform displayed on the oscilloscope resembles
andthefrequencyisequalto+32.5KHz±20%;
±
±
WARNING!
A) Loadlesstest:
Fig. E
1.2 Scheduled tests
- the output voltage over dinse + and dinse is equal to 95Vdc
10%.
- set up the ohmic load with the switch settings as in the table in
;
- on the front panel position the current potentiometer on
minimum(turnanti-clockwiseasfarasitwillgo);
- switchonthemainswitch;
- startupontheohmicloadandmakesurethat:
- the waveforms displayed on the oscilloscope resemble
thosein ;
- the output current is equal to +5Adc 20% and the output
voltageisequalto+20.2Vdc %.
- switchofftheohmicloadandswitchoffthemainswitch.
- set up the ohmic load with the switch settings as in the table in
;
- onthefront panelposition thecurrentpotentiometeronapprox.
80A;
- startuptheohmicloadandmakesurethat:
- the waveforms displayed on the oscillscope resemble
thosein ;
- the output current is equal to +80Adc 10% andtheoutput
voltageisequalto+23.2.Vdc 10%.
- switchofftheohmicloadandswitchoffthemainswitch.
- the ohmic load with the switch settings according to the
relevantTechnologymodel(seetablesin );
- on the front panel position the current potentiometer on
maximum(turnclockwiseasfarasitwillgo)
- startupontheohmicloadandmakesurethat:
- the waveforms displayed on the oscillscope resemble those in
;
- the output current is equal to +130Adc ±3% and the output
voltageis equalto+25.2Vdc ±5%;ifthe outputcurrentreading
is not 130A ±3%, adjust the current using trimmer IMAX R13
ontheprimaryboard( ).
B) Ratedloadtest:
fig.G
Fig.F
C) Intermediateloadtest:
fig.G
Fig.G
A) Ratedloadtest:
Figs.H,I,J,K
Fig.H
fig.3
For the Technology 150
±
±
±10
-15-
TECHNOLOGY 150-170-200-186CE/GE
TECHNOLOGY 150-170-200-186CE/GE
FIGURE E
SETTINGS
· THE FREQUENCY IS
60KHz ±5%;
· AMPLITUDE CH1 IS
340V ±10%;
:
· PROBE CH1 x100;
· 100 V/Div;
· PROBE CH4 =1A;
· 10mV/Div;
· 105 sec/Div.µ
VERIFY THAT
Number switch
Position switch
FIGURE E
6
3
2
145
333222
FIGURE H
SETTINGS
· THE FREQUENCY IS
32.5KHz ±20%;
· AMPLITUDE CH1 IS
340V ±10%;
· AMPLITUDE CH4 IS
56A ±10%;
:
· PROBE CH1 x100;
· 100 V/Div;
· PROBE CH4 =20A;
· 10mV/Div;
· 10 sec/Div.µ
VERIFY THAT
FIGURE E
FIGURE F
6
3
2
145
100000Number switch
Position switch
SETTINGS
· THE FREQUENCY IS
60KHz ±5%;
· AMPLITUDE CH1 IS
340V ±10%;
· AMPLITUDE CH4 IS 7A
±20%;
:
· PROBE CH1 x100;
· 100 V/Div;
· PROBE CH4 =5A;
· 10mV/Div;
· 10 sec/Div.µ
VERIFY THAT
Number switch
Position switch
FIGURE E
6
3
2
145
222210
FIGURE G
SETTINGS
· THE FREQUENCY IS
60KHz ±5%;
· AMPLITUDE CH1 IS
340V ±10%;
· AMPLITUDE CH4 IS
26A ±20%;
:
· PROBE CH1 x100;
· 100 V/Div;
· PROBE CH4 =20A;
· 10mV/Div;
· 10 sec/Div.µ
VERIFY THAT

For the Technology 170
For the Technology 200
- the waveforms displayed on the oscillscope resemble those in
;
- the output current is equal to +160Adc ±3% and the output
voltageis equalto+26.4Vdc±5%;iftheoutputcurrent reading
is not 160A ±3%, adjust the current using trimmer IMAX R13
ontheprimaryboard( ).
- the waveforms displayed on the oscillscope resemble those in
;
- the output current is equal to +180Adc ±3% and the output
voltageis equalto+27.7Vdc±5%;iftheoutputcurrent reading
is not 180A ±3%, adjust the current using trimmer IMAX R13
ontheprimaryboard( ).
Fig.I
fig.3
Fig.J
fig.3
For the Technology 186CE/GE
- the waveforms displayed on the oscillscope resemble those in
;
- the output current is equal to +145Adc ±3% and the output
voltageis equalto+25.8Vdc±5%;iftheoutputcurrent reading
is not 145A ±3%, adjust the current using trimmer IMAX R13
ontheprimaryboard( ).
- switchofftheohmicloadandswitchoffthemainswitch.
- set up the dual trace oscilloscope, connecting probe CH1 x
100 to the anode of diode D1 or D2 and probe CH2x100 to the
anode of diode D3 or D5.Earth connections are both made to
thesecondarydissipator;
- remove the multimeter from the OUT+ and OUT- bump
contacts;
- set up the ohmic load with the switch settings according to the
relevantTechnologymodel(seetablesatpoint1.2D);
- on the front panel position the current potentiometer R7 to the
maximum (turn the knob clockwise as far as it will go) and
switchonthemainswitch;
- activate the static load generator and make sure that the
waveforms displayed on the oscilloscope resemble those in
- deactivate the static load generator and switch off the main
switch.
Set up the ohmic load as shown in the table in and the
current potentiometer on approx. 80A. Position switch SW1 on
HARD (in the centre), start the ohmic load and make sure the
output current reading shows approx.110A ±10% then returns to
thecurrentsetting
.
OnthefrontpanelsetswitchSW1toSOFT(aslowasit willgoand
the welding current to maximum). Under the relevant load
Fig.K
fig.3
E) Checkingthesecondarydiodevoltages:
fig.L;
A)Arc Force test Fig. G
B)Runningtimetestandclosingthemachine
1.3 Operational tests
-16-
FIGURE E
6
3
2
145
333332
FIGURE J
TECHNOLOGY 150-170-200-186CE/GE
Number switch
Position switch
FIGURE E
FIGURE I
Number switch
Position switch
6
3
2
145
333222
SETTINGS
· THE FREQUENCY IS
32.5KHz ±20%;
· AMPLITUDE CH1 IS
340V ±10%;
· AMPLITUDE CH4 IS
60A ±10%;
:
· PROBE CH1 x100;
· 100 V/Div;
· PROBE CH4 =20A;
· 10mV/Div;
· 10 sec/Div.µ
VERIFY THAT
FIGURE E
6
3
2
145
333222
FIGURE K
Number switch
Position switch
SETTINGS
· THE FREQUENCY IS
32.5KHz ±20%;
· AMPLITUDE CH1 IS
340V ±10%;
· AMPLITUDE CH4 IS
58A ±10%;
:
· PROBE CH1 x100;
· 100 V/Div;
· PROBE CH4 =20A;
· 10mV/Div;
· 10 sec/Div.µ
VERIFY THAT
SETTINGS
· THE FREQUENCY IS
32.5KHz ±20%;
· AMPLITUDE CH1 IS
340V ±10%;
· AMPLITUDE CH4 IS
60A ±10%;
:
· PROBE CH1 x100;
· 100 V/Div;
· PROBE CH4 =20A;
· 10mV/Div;
· 10 sec/Div.µ
VERIFY THAT
FIGURE E
FIGURE L
SETTINGS
· REVERSE AMPLITUDE
ON CH1
250V.
· REVERSE AMPLITUDE
ON CH2
250V.
:
· PROBE CH1 x100;
· 50V/Div;
· PROBE CH2 x100;
· 50V/Div;
· 10 sec/Div.µ
VERIFY THAT
DOES NOT
EXCEED
DOES NOT
EXCEED

conditionsforthe particularTechnology model(seetablesat point
1.2 D), switch on the machine and leave it running until the
thermostatic capsules trigger (machine in alarm). After making
sure the internal wiring is positioned correctly assemble the
machineonceandforall.
with the machine set up according to the instructions in the
handbook make a test weld with an electrode diam. 2.5 and the
currentsettingat80A.Monitorthedynamicbehaviourofthepower
source, also checking for the presence of the Arc Force SW1 on
HARD(inthecentre)
C)Weldingtest
MMA:
TECHNOLOGY 150-170-200-186CE/GE
TECHNOLOGY 150-170-200-186CE/GE
FIG. 1A
FIG. 1B
ILLUSTRATIONS
TO
COVER SCREWS
TOP
COVER SCREWS
TOP
COVER SCREWS
- 17-
SCREWS
FASTENING
BACK PANEL
SCRAWS
FASTENING
BACK PANEL
SCREWS
FASTENING
FRONT PANEL
SCREWS
FASTENING
FRONT PANEL

-18-
TECHNOLOGY 150-170-200-186CE/GE
FIG. 2A
FIG. 2B
POSITIVE DINSE
D9
YELLOW LED
ALARM
BOTTOM
COVER SCREWS
NEGATIVE DINSE
SW1
SWITCH
SELECTION
TIG/LIFT-HARD-SOFT
BOTTOM
COVER SCREWS
BOTTOM
COVER SCREWS
BOTTOM
COVER SCREWS
MAINS CABLE
GENERAL SWITCH
FAN
CURRENT
POTENTIOMETER
BOTTOM
COVER SCREWS

-19-
TECHNOLOGY 150-170-200-186CE/GE
TECHNOLOGY 150-170-200-186CE/GE
FIG. 4
FIG. 3
D4 D8 R6 Q4, Q3 D5, D3
CN10 C7, C2, C4, C6 JP1 U2 R40B Q10
ISO2, ISO1 Q2, Q1 R2 R1 K2, K1 R13 D32 D9 U4 U6
D1, D2 SHUNT R1
R1, C1
D3, D5 THERMOSTAT
CABLE
ST1
SW1 R16
CN3 HYBRID BOARD

-20-
TECHNOLOGY 150-170-200-186CE/GE
ELENCO PEZZI DI RICAMBIO - LISTE PIECES DETACHEES
SPARE PARTS LIST - ERSATZTEILLISTE - PIEZAS DE REPUESTO
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.
Esploso macchina, Dessin appareil, Machine drawing, Explosions Zeichnung des Geräts, Diseño seccionado maquina.
15
25
27
19
13
8
16
20
1 5 21 14
26 6 9 18
107423122317
11 24 22