Telwin TECNICA 114 Operating instructions

cod. 988656
TECNICA 140.1 - 142
inverter
TECNICA 114
CONTENTS PAGE
OPERATION AND WIRING DIAGRAMS................ 2
REPAIR GUIDE...................................................... 9
SPARE PARTS LIST...............................................17
REPAIR SHEET......................................................19
Block diagram 2
Analysis of the block diagram 3
Illustrations 5
Wiring diagrams 6
Equipment required 9
General repair instructions 10
Troubleshooting and remedies 10
Testing the machine 13
Illustrations 15
TROUBLESHOOTING
AND REPAIR MANUAL
TROUBLESHOOTING
AND REPAIR MANUAL
TROUBLESHOOTING
AND REPAIR MANUAL
TROUBLESHOOTING
AND REPAIR MANUAL
“reparation no problem !”

TECNICA 114
-2-
BLOCK DIAGRAM
OPERATION AND WIRING DIAGRAMSOPERATION AND WIRING DIAGRAMS
OPERATION AND WIRING DIAGRAMSOPERATION AND WIRING DIAGRAMS
6
CURRENT
TRANSFORMER
1
EMC FILTER
7
POWER
TRANSFORMER
19
CURRENT
POTENTIOMETER
22
GALVANIC
SEPARATION
11
ALIMENTATORE
FLY-BACK
12
AUXILIARY
POWER
SUPPLY
25 POWER
SUPPLY LED
26
FAN
15
DUTY CYCLE MAKER
16
ADDER
17
ALARM BLOCK
2
PRE-CHARGE
3
RECTIFIER BRIDGE
4
FILTER
5
CHOPPER
8
8
SECONDARY
DIODE
9
INDUCTANCE
OUTPUT
14
PRIMARY
CURRENT READER
AND LIMITER
13
DRIVER
10
SECONDARYEMC
FILTER
INPUT
11
AUXILIARY POWER
SUPPLY TRIGGER
18
ALARM LED
23
t
OVERVOLTAGE
SAFEGUARD
21
IGBT THERMOSTAT
20
MAXIMUM
CURRENT
ADJUSTMENT
24 UNDERVOLTAGE
SAFEGUARD

-3-
ANALYSIS OFTHE BLOCK DIAGRAM
NOTE: Unless indicated otherwise, it should be assumed
thatthecomponentsareassembledonthepowerboard.
Consistingof:C1,C8,C9,L1.
Prevents noise from the machine from being transmitted
alongthemainpowerlineandviceversa.
Consistingof:K1,R2.
Preventstheformation ofhightransitorycurrentsthatcould
damage the main power switch, the rectifier bridge and the
electrolyticcapacitors.
When the power source is switched on the relay K1 is de-
energised, capacitors C2, C3, C4 are then charged by R2.
Whenthecapacitorsarechargedtherelayisenergised.
Consistingof:D1.
Converts the mains alternating voltage into continuous
pulsedvoltage.
Consistingof:C2,C3,C4.
Converts the pulsed voltage from the rectifier bridge into
continuousvoltage.
Consistingof:Q1.
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:T2.
The C.T. is used to measure the current circulating in the
power transformer primary and transmit the information to
block17(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 thepower
supplyline).
Consistingof:D22
Diode D22 converts the current circulating in the
transformer to a single direction, preventing saturation of
the nucleus, and recirculates the inductance output current
(block 9) during the time when the IGBT's are not
conducting,bypassingthepowertransformer(block7).
Block 1
Block 2
Block 3
Block 4
Block 5
Block 6
Block 7
Block 8
EMC Filter
Pre-charge
Rectifier bridge
Filter
Chopper
Current transformer
Power transformer
Secondary diode
Block 9
Block 10
Block 11
Block 12
Block 13
Block 14
Block 15
Block 16
Block 17
Inductance
Secondary EMC Filter
Auxiliary power supply trigger
Auxiliary power supply
Driver
Primary current reader and limiter
Duty cycle maker
Adder
Alarm Block
Consistingof:L2.
Levelsthesecondaryboarddiodes’outputcurrentmakingit
practicallycontinuous.
Consistingof: C23,C24.
Prevents noise from the power source from being
transmittedthroughtheweldingcablesandviceversa.
Consistingof:R13,R14,R15,C13
Via the resistors, the power source supplies the necessary
voltagetopowerblock12(auxiliarypowersupply).
Consistingof:D10,C11,Q11,D11
Rectifies, filters and stabilises the voltage arriving from the
tertiarywindingofthepowertransformer(block7).
Consistingof:Q6,Q7,D46,D47
Picksupthesignalarrivingfromblock15(dutycyclemaker)
adjustsittosuitpilotingofblock5(chopper).
Consistingof: D42,D45,R56,C44,R57,R58,R59.
Reads the signal from block 6 (current transformer) and
scales it down so it can be processed and compared in
blocks15and16.
Consistingof:U3,U2B.
Processes the information from block 16 (adder) and block
14 (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.
Consistingof:U1D.
Gathers all the information from block 14 (primary current
reader and limiter), from block 17 (alarms) and from block
19 (current potentiometer), and produces a signal with a
suitable voltage for processing by block 15 (duty cycle
maker).
Consistingof:Q3,U1A,U1C.
Whenanalarm isdetected thepowersourceoutput current
isdrasticallyreduced bymakingdirectadjustments to block
15 (duty cycle maker) and directly changing the reference
signalobtainedfromblock19(currentpotentiometer).
TECNICA 114

-4-
Block 26
Fan
Consistingof:V1.
Powered directly by block 12 (a ) and
coolsthepowercomponents. uxiliary power supply
Block 18
Block 19
Block 20
Block 21
Block 22
Block 23
Block 24
Block 25
Alarm LED
Current potentiometer
Maximum current adjustment
IGBT Thermostat
Galvanic separation
Overvoltage safeguard
Undervoltage safeguard
Power supply LED
Consistingof:D35.
Itisswitchedonbyblock17(alarms)intheeventof:
1) Triggering of thermostatic capsule/thermostat on power
transformer.
2) Triggeringofthermostaticcapsuleonsecondarydiodes.
3) Triggeringduetoovervoltage.
4) Short circuitat output (electrodeholder clamp and earth
cable connected to one another or electrode stuck to
piecebeingwelded).
Consistingof:R75.
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.
Consistingof:R70,R71,R72,R73,R74.
Used to adjust the maximum cutting current to be supplied
bythepowersource.
Consistingof:ST1
When the temperature of the IGBT dissipator reaches a
giventemperaturethe thermostatcutsin,sending analarm
signal to block 22 (galvanic separation). It is reset
automatically when this alarm condition is no longer
present.
Consistingof:ISO1
The signal arriving from blocks 21 (IGBT thermostat) is
separated galvanically and sent to block 17 (alarms) for
detectionofapossiblealarmevent.
Consistingof:R40,R41,R42,Q3.
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
safeguardtriggers).
Consisting of: R63, R64, U1C, Q8.
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).
Consistingof:D34.
Indicates when the power source is correctly powered and
readyforuse.
TECNICA 114

-5-
Power boad
TECNICA 114
ILLUSTRATIONS
(13)
DRIVER
(3)
RECTIFIER
BRIDGE
(6)
CURRENT
TRANSFORMER
(4)
FILTER
(1)
EMC FILTER
(5)
CHOPPER
(7)
POWER
TRANSFORMER
(10)
SECONDARY
EMC FILTER
(8)
SECONDARY
DIODE
(2)
PRE-CHARGE
(25)
POWER
SUPPLY LED
(18)
ALARM
LED
(9)
INDUCTANCE
(12)
AUXILIARY POWER
SUPPLY
(19)
CURRENT
POTENTIOMETER
(16)
(17)
ADDER
ALARM BLOCK
(15)
DUTY CYCLE
MAKER

-6-
TECNICA 114
WIRING DIAGRAMS
General wiring diagram
POWER PCB
100/115V OR 230V ON L Y
MODELS WITH POWER SUPPLY CHANGE
+J4+J4
-J4-J4
J7J7
230V230V 115V115V
P4P4
PE
L1
N (L2)
V1
Fan
V1
Fan
J1J1 J2J2
OUT+OUT+
J3J3
OUT-OUT-
5
4
12
S1
ON/OFF
5
4
12
S1
ON/OFF

-7-
TECNICA 114
Wiring diagram power board – power supply

CN1 -9
CN1 -5
CN1 -2
CN1 -9 CN1 -3 CN1 -5 CN1 -8
CN1 -8
CN1 -4
CN1 -4
CN1 -6
CN1 -3
CN1 -2
CN1 -6
RIL-I
CN1 -6
OU TN
VA+
B-Q8
E-Q5
B-Q5
CN1 -7
SOV -T
CN1 -1
OU TP
DC -
STS_B STS_A
+12 V
+12 V
+5V
+12 V
+5V +12 V
+5V
+12 V
+12 V
Termostati
R17
22K 0805 5%
R17
22K 0805 5%
R19
33K 1206 5%
R19
33K 1206 5%
Vcc
7
VFB
2
Isen
3
GND
5OU T 6
COM P 1
VREF 8
RT/CT 4
U1
UC3845AD
U1
UC3845AD
R58
120R 0805 5%
R58
120R 0805 5%
R5
33K 1206 5%
R5
33K 1206 5%
R14
33K 1206 5%
R14
33K 1206 5%
R1
33K 1206 5%
R1
33K 1206 5%
D24
10V 0W 4 5%
D24
10V 0W 4 5%
R13
4K 7 0805 5%
R13
4K 7 0805 5% D28
BYG20G
D28
BYG20G
12
3D38
BAV99
D38
BAV99
R15
100R 0805 5%
R15
100R 0805 5%
R26
14K 7 0805 1%
R26
14K 7 0805 1%
R6
100R 0805 5%
R6
100R 0805 5%
D15
18V 0W 4 5%
D15
18V 0W 4 5%
R9
680R 0805 5%
R9
680R 0805 5%
C26
1u 25V Z 5U
C26
1u 25V Z 5U
R47
1K 0805 5%
R47
1K 0805 5%
1
23
Q7
BC807
Q7
BC807
R32
10K 0805 5%
R32
10K 0805 5%
D29
18V 0W 4 5%
D29
18V 0W 4 5%
C11
1u 25V Z 5U
C11
1u 25V Z 5U
D37
4V7 0W 4 2%
D37
4V7 0W 4 2%
D19
BYG20G
D19
BYG20G
D16
18V 0W 4 5%
D16
18V 0W 4 5%
R16
1K 0805 5%
R16
1K 0805 5%
R59
470R 0805 5%
R59
470R 0805 5%
D25
BYG20G
D25
BYG20G
R48
47R 0805 5%
R48
47R 0805 5%
R42
1K 0805 5%
R42
1K 0805 5%
R28
680R 0805 5%
R28
680R 0805 5%
R52
3K 3 1206 5%
R52
3K 3 1206 5%
R20
680R 0805 5%
R20
680R 0805 5%
D22
10V 0W 4 5%
D22
10V 0W 4 5%
D23
BYG20G
D23
BYG20G
1
23
Q2
BC817
Q2
BC817
R33
220K 0805 5%
R33
220K 0805 5%
R2
200R 1 T 0W 5 10%
R2
200R 1 T 0W 5 10%
R43
10K 0805 5%
R43
10K 0805 5%
D18
BYG20G
D18
BYG20G
1 2
3
D7
BAV99
D7
BAV99
C3
100p 50V X7R
C3
100p 50V X 7R
D27
BYG20G
D27
BYG20G
R50
2K208055%
R50
2K208055% R22
2K 2 0805 5%
R22
2K 2 0805 5%
R61
10R 1206 5%
R61
10R 1206 5%
1
23
Q6
BC807
Q6
BC807
R3
100R 0805 5%
R3
100R 0805 5%
1
2 3
Q1
BC817
Q1
BC817
D17
18V 0W 4 5%
D17
18V 0W 4 5%
R56
120R 0805 5%
R56
120R 0805 5%
12 13 14
411
U2D
LM 324
U2D
LM 324
R49
1K 1206 5%
R49
1K 1206 5%
D26
BYG20G
D26
BYG20G
R38
2K208055%
R38
2K208055%
D30
18V 0W 4 5%
D30
18V 0W 4 5%
D4
24V 0W 4 5%
D4
24V 0W 4 5%
R44
4K7 0805 5%
R44
4K7 0805 5%
C14
100n 50V X7R
C14
100n 50V X7R
R30
4K 7 0805 5%
R30
4K 7 0805 5%
R24
33K 1206 5%
R24
33K 1206 5%
R27
10K 0805 5%
R27
10K 0805 5%
R11
4K 7 0805 5%
R11
4K 7 0805 5%
R57
6K8 5W 5%
R57
6K8 5W 5%
Q4
IR FD 110
Q4
IR FD 110
1
2
3
D6
BAV99
D6
BAV99
C31
1u 25V Z 5U
C31
1u 25V Z 5U
R51
3K 3 1206 5%
R51
3K 3 1206 5%
R25
27R 1W 5%
R25
27R 1W 5%
1
2
3
D5
BAV99
D5
BAV99
R34
1K 0805 5%
R34
1K 0805 5%
R53
1K 0805 5%
R53
1K 0805 5%
R10
470R 0805 5%
R10
470R 0805 5%
C13
100n 50V X7R
C13
100n 50V X7R
1
23
Q9
BC807
Q9
BC807
C2
100p 50V X 7R
C2
100p 50V X 7R
C10
100n 50V X7R
C10
100n 50V X7R
10
98
411
U2C
LM 324
U2C
LM 324
3 21
411
U2A
LM 324
U2A
LM 324
C23
100n 50V X7R
C23
100n 50V X7R
R7
10K 0805 5%
R7
10K 0805 5%
R36
2K208055%
R36
2K208055%
C29
100u 35V A ll
C29
100u 35V A ll
R21
14K 7 0805 1%
R21
14K 7 0805 1%
R55
470R 0805 5%
R55
470R 0805 5%
R31
100K 0805 5%
R31
100K 0805 5%
R29
22K 1206 5%
R29
22K 1206 5%
C19
100n 50V X7R
C19
100n 50V X7R
R54
10R 1206 5%
R54
10R 1206 5%
1
2
3
D1
BAV99
D1
BAV99
D20
BYG20G
D20
BYG20G
1 8
6 5 4 3
T1
T I 120023
T1
T I 120023
C24
1n 50V N PO
C24
1n 50V N PO
R62
1K 0805 5%
R62
1K 0805 5%
C4
4u7 16V T AN
C4
4u7 16V T AN
C12
10n 50V X7R
C12
10n 50V X7R
2 14
3
ISO 1
TLP621
ISO 1
TLP621
D3
4V7 0W 4 5%
D3
4V7 0W 4 5%
5 67
411
U2B
LM 324
U2B
LM 324
C5
1n 50V N PO
C5
1n 50V N PO
12
3
D2
BAV99
D2
BAV99
1 2 3 4 5 6 7 8 9 10 11 12
TestPoint
12 F o r i P a sso 2 .54mm
TestPoint
12 F o r i P a sso 2 .54mm
R12
10K 0805 5%
R12
10K 0805 5%
C6
100n 50V X7R
C6
100n 50V X7R
1
2 3
Q3
BC817
Q3
BC817
R23
10K L in 0W 2 20%
R23
10K L in 0W 2 20%
C9
1n 50V N PO
C9
1n 50V N PO
C7
100n 50V X7R
C7
100n 50V X7R
-8-
TECNICA 114
Wiring diagram power board – driver / control

42513
6
-9-
TECNICA 114
REPAIR GUIDEREPAIR GUIDE
REPAIR GUIDEREPAIR GUIDE
EQUIPMENT REQUIRED
(*)The instruments with codes can be supplied by Telwin. The sale price is available on request.
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
5 Unsoldering station
6 Miscellaneous tools

WARNING:
WARNING:
WARNING:
BEFORE PROCEEDING WITH REPAIRS TO THE
MACHINE READ THE INSTRUCTION MANUAL
CAREFULLY.
EXTRAORDINARY MAINTENANCE SHOULD BE
CARRIED OUT ONLY AND EXCLUSIVELY BY
EXPERT OR SKILLED ELECTRICAL-
MECHANICALPERSONNEL.
ANY CHECKS CARRIED OUT INSIDE THE
MACHINE WHEN IT IS POWERED MAY CAUSE
SERIOUS ELECTRIC SHOCK DUE TO DIRECT
CONTACTWITHLIVEPARTS.
GENERAL REPAIR INSTRUCTIONS
TROUBLESHOOTING AND REMEDIES
Thefollowingisalistofpracticalruleswhichmustbestrictly
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 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
GREASILMS12)betweenthecontactzones.
C) The power resistors (should they require replacement)
should always be soldered at least 3 mm above the
board.
D) Ifsiliconeisremovedfromsomepointsonthe boards,it
shouldbere-applied.
Use only non-conducting neutral or oximic
reticulating silicones (e.g. DOW CORNING 7093).
Otherwise, silicone that is placed in contact with points
atdifferentpotential(rheophoresofIGBT's,etc.)should
belefttoreticulatebeforethemachineistested.
E) When the semiconductor devices are soldered the
maximum temperature limits should be respected
(normally300 Cfornomorethan10seconds).
F) It is essential to take the greatest care at each
disassembly and assembly stage for the various
machineparts.
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
endofthismanual).
H) The boards (repaired when necessary) and the wiring
should never be modified without prior authorisation
fromTelwin.
I) For further information on machine specifications and
operation,refertotheInstructionManual.
J) Whenthemachineisinoperationthereare
dangerouslyhighvoltagesonitsinternalpartssodonot
touchtheboardswhenthemachineislive.
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-mechanicalpersonnel.
- undo the 4 screws attaching the handle to the top cover
();
- undo the 2 screws fastening the two plastic shells to the
base:1screwoneachside(
- undo the 2 screws attaching the handle to the base: 1
screwoneachside( );
- on the top cover undo the nut for the earth connection
(J7);
- slideoutthetopcoverupwards( );
- undo the two screws fastening the power board to the
base.
Aftercompletingtherepairs,proceedinthereverseorderto
re-assemble the cover and do not forget to insert the
toothedwasheronthegroundscrew.
Using suitably dried compressed air, carefully clean the
components of the power source since dirt is a danger to
partssubject tohigh voltagesandcandamage thegalvanic
separation between the primary and secondary. To clean
theelectronicboardsweadvisedecreasingtheairpressure
to prevent damage to the components. It is therefore
important to take special care when cleaning the following
parts:
Check whether dirt has been deposited on the front and
back air vents or has damaged the correct rotation of the
blades,ifthereisstilldamageaftercleaningreplacethefan.
Make sure there is no mechanical deformation, dent, or
damaged and/or disconnected connector. Make sure the
powersupplycablehasnotbeendamagedordisconnected
internally and that the fan works with the machine switched
on.Inspect the components and cables for signs of burning
orbreaksthatmayendangeroperationofthepowersource.
Checkthefollowingelements:
Usethe multimeter to checkwhether thecontacts are stuck
togetheroropen.Probablecause:
- mechanical or electric shock (e.g. bridge rectifier or
IGBTinshortcircuit,handlingunderload).
Probablecause:
- mechanicalshock.
Probablecause:
- see main power supply switch. If the relay contacts
are stuck together or dirty, do not attempt to separate
themandcleanthem,justreplacetherelay.
N.B.
WARNING!
fig.1
fig.1);
fig.1
fig.1
N.B.
1.0 Disassembling the machine
2.0 Cleaning the inside of the machine
3.0 Visual inspection of the machine
Fan (fig. 2A)
Power board figs.2A and 2B
Main power supply switch (fig.2A)
Current potentiometer R75 (fig. 3)
Relay K1 (fig. 3)
():
°
-rheoforesofIGBTQ1;
- rheoforesofsecondarypowerdiodeD22;
- thermostatST1ontheIGBT;
- opto-couplerISO1.
-10-
TECNICA 114

Electrolytic capacitors C2,C3 (fig. 3)
IGBT's Q1 (fig. 4)
Secondary diodes D22 (fig. 4)
Power transformer and filter reactance (fig. 2A)
6.1 Preparation for testing
6.2 Scheduled tests for theTECNICA 114 at low voltage
Probablecause
- mechanicalshock;
- machine connected to power supply voltage much
higherthantheratedvalue;
- broken rheophore on one or more capacitor: the
remainder will be overstressed and become damaged
byoverheating;
- ageingafteraconsiderablenumberofworkinghours;
- overheatingcausedbythermostaticcapsulefailure.
Probablecause:
- discontinuationinsnubbernetwork;
- faultindrivercircuit;
- poorly functioning thermal contact between IGBT and
dissipator(e.g.loosenedattachmentscrews:check);
- excessiveoverheatingrelatedtofaultyoperation.
Probablecause:
- discontinuationinsnubbernetwork;
- poorly functioning thermal contact between IGBT and
dissipator(e.g.loosenedattachmentscrews:check);
- faultyoutputconnection.
Inspectthewindingsforcolourchanges.Probablecauses:
- power source connected to a higher voltage than
280Vac;
- ageingafterasubstantialnumberofworkinghours;
- 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, 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
fromthefastonsorconnectors. Ifthepowercablesare
not tight enough this could cause dangerous overheating.
In particular, on the power board it is necessary to make
sure all the wiring is inserted correctly into the
corresponding connectors or fastons. Also make sure that
the connections to the dinse sockets are attached correctly
tothepowerboard.
A) With the multimeter set in mode check
the following components (junction voltages not less than
0.2V):
- rectifierbridgeD1 );
- IGBT's Q1 (absence of short circuits between collector-
gateandbetweenemitter-collector );
- secondary board diodes D22 between anode and
cathode ( ).The secondary diodes can be checked
without removing the power board:with one prod on the
secondary board dissipator diodes and the other in
sequenceonthetwopowertransformeroutlets;
B) Withthemultimetersetinohmmodecheckthefollowing
components:
- resistorR2:47ohm(pre-charge );
- resistorsR3,R4:22ohm (primarysnubber );
- resistorR22:10ohm(secondarysnubber );
- thermostat continuity test on IGBT dissipator:clean the
resinfromthebumpcontactsforST1(A,B) andmeasure
the resistance over these two bump contacts, it should
beapprox0ohm( ).
Before proceeding with troubleshooting, we
shouldremind youthat during thesetests the powersource
is powered and therefore the operator is exposed to the
danger of electric shock.The tests described below can be
used to check operation of the power and control parts of
thepowersource.
A) Set up a multimeter in DC volt mode and connect the
prodstotheOUT+andOUT-bumpcontacts.
B) Position the potentiometer R75 to maximum (clockwise
as far as it will go). to check correct operation of the
control circuit without powering the power board we
recommend carrying out the test given at point 6.2,
otherwisepasstothetestatpoint6.3.
A) Between the cathode of diode D10 (+) and the anode of
diode D11(-) insert a stabilised power supply that is able to
supply40Vdc500mA.
B) Set up the oscilloscope with the voltage probe x100
connected between the gate of Q1 and the earth on the
emitter,alsoofQ1 .
C) Switchon the stabilised powersupply(initially set to 0V)
and gradually increase the generated voltage until it
reaches40Vdc.
D) Make sure the waveform shown on the oscilloscope
resembles . if the signal is not present it may be
necessary to replace component Q1 or, alternatively, the
drivercircuitU3,Q6andQ7( ).
E) Setupamultimeterinvoltmodeandmakesurethat(
):
- thevoltageoverpins2and1ofJ8isequalto+23V±5%;
- the voltage over pins 5 and 1 of J8 is equal to +5Vdc
±5%;
- thevoltageoverpins4and1ofJ8 isequalto+500mVdc
±5%;
- thevoltageoverpins8and1ofJ8isequalto0Vdc.
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
N.B.
diode testing
(fig.3
fig.4
fig. 4
fig.3 fig.3
fig.3
fig.2B
WARNING!
N.B.
(fig.3)
fig.A N.B.
fig.3 fig.
3
(NoC3on230VversionofTecnica114):
-11-
TECNICA 114
FIGURE A
SETTINGS:
· PROBE CH1 x10;
· 5 V/Div;
· 10 sec/Div.
·:
60KHz ±10%.
· POSITIVE
AMPLITUDE IS
+16V ±10%;
· NEGATIVE
AMPLITUDE IS
-5V ±10%.
µ
VERIFY THAT:
THE FREQUENCY IS

6.3 Scheduled tests for theTECNICA 114 (230V)
6.4 Scheduled tests for theTECNICA 114 (115V)
7.1 Removing the power board (fig.2A)
A) Disconnect the stabilised power supply from the power
board.
B) Set up the dual trace oscilloscope.Connect probe CH2
(x100) to the collector of Q1 and probe CH1 (x10) to the
gate, also of Q1. The earth terminals are connected
togethertotheemitterofQ1.
C) Connect the power supply cable to a single phase
variacwithvariableoutput0-300Vac.
D) Switch on the variac (initially set to 0V), close the main
power supply switch on the power source and gradually
increasethevoltagegeneratedbythevariacuntilitreaches
230Vacthenmakesurethat:
- thegreenpowersupplyLEDD34lightsup( );
- thefanstartstoturnforthepowertransformer;
- pre-chargerelayK1closes( );
- for voltages close to the rated power supply value
(230Vac ±15%) the power source does not signal an
alarm(yellowLEDD35off).
if the alarm persists in the power source this could be
due to a fault in the control components (in any case
proceedtomakefurthertests).
E) Make sure the waveform shown on the oscilloscope
resembles . if the signal is not present it may be
necessary to replace component Q1 or, alternatively, the
drivercircuitU3,Q6andQ7( ).
F) Setupamultimeterinvoltmodeandmakesurethat(
):
- the voltage over pins 2 and 1 of J8 is equal to +23Vdc
±5%;
- the voltage over pins 5 and 1 of J8 is equal to +5Vdc
±5%;
- thevoltageoverpins 4and1ofJ8isequalto+500mVdc
±5%;
- thevoltageoverpins8and1ofJ8isequalto0Vdc;
- the output voltage over OUT+ and OUT- is equal to
+80Vdc±10%.
G) Set up the dual trace oscilloscope.Connect the voltage
probe x100 between the gate of Q1 and the earth to the
emitter, also of Q1 ( ).Probe CH2 (x10) to the rheofore
ofR55towardsC11andtheearthtotheanodeofD11.
H) Make sure the waveform shown on the oscilloscope
resembles .
I) Switchthepowersourceoffandonagainandmakesure
that, after the transitory switch-on time, there is no alarm
(yellowalarmLEDD12isoff ) Ifanalarmpersists
(andisnotcausedbyafaultinthecontrolboard)therecould
beafaultintheopto-couplerISO1( ).
Power the power source at the rated voltage of
115Vac.Inthiscasethetests areexactlythesameasthose
for the Tecnica 114 (230V) and can be carried out in the
sameway.
Ifthefaultisinthepowerboardremoveitfromthebottomas
follows:
- with the machine disconnected from the main supply,
disconnectallthewiringconnectedtotheboard;
- removethecurrentadjustmentknobonthefrontpanelof
themachine( );
- remove any bands constraining the board (e.g. on the
powersupplycableandconnectionstoprimary);
- fromthe welding sideundo the twoscrewsfasteningthe
dinsesocketstotheprintedcircuitboard( ).
- undothe2screwsfasteningtheboardtothebottom(
).
- undo the 2 screws fastening the board to the front and
backontheinside( ).
- after removing the screws, lift the board upwards to
removeitfromthebottomofthemachine.
to re-assemble, proceed in the reverse order,
remembering to insert the toothed washers on the earth
screws.
fig.3
fig.3
N.B.
fig. B N.B.
fig.3
fig.
3
fig.3
fig.C
fig.3 .N.B.
fig.3
WARNING!
fig.1
fig.2B fig.
2B
fig.2B
N.B.
7.0 Repairs,replacingtheboards
Ifrepairingtheboard iscomplicated orimpossible,itshould
be completely replaced.The board is identified by a 6-digit
code (printed in white on the component side after the
initials TW). This is the reference code for requesting a
replacement:Telwinmaysupplyboardsthat arecompatible
butwithdifferentcodes.
beforeinsertinganewboardcheckitcarefullyfor
damage that may have occurred in transit.When we supply
a board it has already been tested and so if the fault is still
presentafter ithas been replacedcorrectly,checkthe other
machine components. Unless specifically required by the
procedure,neveraltertheboardtrimmers.
Warning:
-12-
TECNICA 114
FIGURE B
SETTINGS :
· PROBE CH1 x10;
· 10 V/Div;
· PROBE CH2 x100;
· 200 V/Div;
· 5 sec/Div.
TIME TOLLERANCES:
±20%.
· AMPLITUDE CH2
IS 320V ±10%;
· POSITIVE
AMPLITUDE CH1
IS +18V ±10%;
· NEGATIVE
AMPLITUDE CH1
IS -10V ±10%.
µ
VERIFY THAT
FIGURE C
SETTINGS:
· PROBE CH1 x100;
· 200V/Div;
· PROBE CH2 x10;
· 500mV/Div;
· 5 sec/Div.
TIME TOLLERANCES:
±20%.
· AMPLITUDE CH1 IS
640V ±10%;
· AMPLITUDE CH2 IS
500mV ±50%;
µ
VERIFY THAT

A) Take special note of the procedure for replacing the
IGBT(fig.4):
fig.2B
ohms
B) Take special note of the procedure for replacing the
secondarydiodes(fig.4):
N.B. fig.3
WARNING!
WARNING!
A) Minimumloadtest:
fig.D
fig.D
- to replace the IGBT undo the screws fastening the
dissipatortotheboard( );
remove IGBT Q1 by unsoldering the rheofores and also
removethesolderfromthebumpcontactsonthePCB;
- removethedissipatorfromtheboard;
- undothescrewsholdingtheIGBT.
Beforeproceedingwiththe replacementmakesurethatthe
partspilotingtheIGBTarenotdamagedaswell:
- withthemultimeterseton checkthePCBtomake
sure there is no short circuit between the 1st and 3rd
bump contacts (between gate and emitter)
correspondingtoeachcomponent;
- alternatively, resistors R8 and R9 could have blown
and/or diodes D8 and D9 may be unable to work at a
correctZenervoltage(thisshouldhavebeendetectedin
thepreliminarytests);
- clean any irregularities or dirt from the dissipator. If the
IGBT module has blown the dissipator may be
irreparably damaged: in such a case it should be
replaced;
- apply thermoconductive paste following the general
instructions;
- attach the new IGBT to the dissipator with the screw
(torquewrenchsetting1Nm±20%);
- place the dissipator with the new IGBT on the bump
contacts of the PCB, interposing, and attach it with the
screws(torquewrenchsetting1Nm±20%);
- solder the terminals taking care not to let the solder run
alongthem;
- on the solder side cut the protruding part of the
rheofores and make sure they have not shorted
(betweenthegateandemitterinparticular).
- undothescrewsfasteningthedissipatortotheboard;
- remove the secondary diodes by unsoldering the
rheofores and also remove the solder from the bump
contactsonthePCB;
- removethedissipatorfromtheboard;
- removethespringslockingthediode;
- clean any irregularities or dirt from the dissipator. If the
diode has blown the dissipator may have been
irreparably damaged: in such a case it should be
replaced;
- apply thermoconductive paste following the general
instructions;
- insert the new diode between the dissipator and the
spring,takingcarenottodamagethecomponentduring
assembly (the spring should be inserted by pressure on
thedissipatorinordertolockthecomponent);
- place the dissipator with the new component on the
bump contacts of the PCB, and attach it with the screws
(torquewrenchsetting1Nm±20%);
- solder the terminals taking care not to let the solder run
alongthem;
- on the soldering side cut the protruding part of the
rheofores and make sure they have not shorted
(betweencathodeandanode).
make sure that resistor R22 and capacitor C22 of the
snubberaresolderedcorrectlytothePCB( ).
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
activatetheohmicloadcontactor.
Before proceeding to test the machine, we
shouldremind youthat during these teststhe powersource
is powered and therefore the operator is exposed to the
dangerofelectricshock.
The tests given below are used to verify power source
operationunderload.
A) Connect the power source to the static load generator
(code802110)usingcablesfittedwiththeappropriatedinse
connectors.
B) Set up the dual trace oscilloscope.Connect the voltage
probe x100 between the gate of Q1 and the earth to the
emitter, also of Q1.Probe CH2 (x10) to the rheofore of R55
towardsC11andtheearthtotheanodeofD11.
C) Set up a multimeter in DC volt mode and connect the
prodstotheOUT+andOUT-bumpcontacts.
D) Connect the power supply cable to the main 230Vac
powersupply.
during testing prevent contact with the metal
part of the torch because of the presence of high voltages
thatarehazardoustotheoperator.
- set up the ohmic load with the switch settings as in the
tablein ;
- on the front panel turn the current potentiometer to
minimum(turnanti-clockwiseasfarasitwillgo);
- switchonatthemainswitch;
- startuptheohmicloadandmakesurethat:
- the waveforms displayed on the oscilloscope
resemblethosein ;
- the output current is equal to +9Adc ±5% and the
outputvoltageisequalto+15Vdc±5%;
- switchofftheohmicloadandswitchoffthemainswitch.
-
1.1 Preparation for testing
1.2 Scheduled tests for theTECNICA 114 (230V)
TESTINGTHE MACHINE
-13-
TECNICA 114
SETTINGS:
· PROBE CH1 x 100
· 200V/Div;
· PROBE CH2 x10;
· 500mV/Div;
· 5 /Div.
TOLERANCES:
· FOR TIME 20%.
· PEAK AMPLITUDE
CH1 600V 10%.
· PEAK AMPLITUDE
CH2 900mV 30%.
µsec
±
±
VERIFY THAT:
FIGURE D
Posizione commutatore
Numero commutatore
1
1
2
0
3456
0000

B) Intermediateloadtest:
fig.E
fig.E
C) Ratedloadtest:
fig.F
fig.F
fig.5
D) Checkingthesecondarydiodevoltages:
fig.F
fig.H
E) Runningtimecheckandclosingthemachine
fig. F
F) Weldingtest
- set up the ohmic load with the switch settings as in the
tablein ;
- on the front panel turn the current potentiometer to 40A
(approx.Half-way);
- switchonatthemainswitch;
- startuptheohmicloadandmakesurethat:
- the waveforms displayed on the oscilloscope
resemblethosein ;
- the output current is equal to +40Adc ±10% and the
outputvoltageisequalto+21.6Vdc±10%;
- switchofftheohmicloadandswitchoffthemainswitch.
- set up the static load generator with the switch settings
asinthetablein ;
- on the front panel turn the current potentiometer to
maximum(turnclockwiseasfarasitwillgo);
- to the maximum (turn the knob clockwise as far as it will
go)andswitchonthemainswitch;
- activatethestatic loadgeneratorandmakesurethat:
- the voltage waveforms on the oscilloscope display
resemblethosein ;
- the output current is equal to 75Adc ±5% and the
output voltage is equal to +23.6Vdc ±5%; if the
output current reading is not 75A ±5%, adjust the
currentusingjumpersJP1,JP2andJP3( ).
- switchofftheohmicloadandswitchoffthemainswitch
- set up the dual trace oscilloscope by connecting probes
CH1 and CH2 x100 to the two secondary outputs of the
power transformer. The earth terminals are connected
togethertothesecondarydissipator;
- remove the multimeter from the OUT+ and OUT- bump
contacts;
- set up the ohmic load with the switch settings as in the
tablein ;
- switchonatthemainswitch;
- on the front panel turn the current potentiometer to
maximum(turnclockwiseasfarasitwillgo);
- startuptheohmicloadandmakesurethewaveforms;
- displayedontheoscilloscoperesemblethosein ;
- switchofftheohmicloadandswitchoffthemainswitch.
With the load status as in 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
positioningoftheinternalwiringandfinallyre-assemblethe
machine.
With the power source set up according to the instructions
in the handbook make a test weld at 40¸70A (electrode
diameter 2.5 mm). Check the dynamic behaviour of the
powersource.
1.3 Tests for theTECNICA 114 (115V)
Power the power source at the rated voltage of
115Vac.Inthiscasethe testsareexactlythesameas those
for the TECNICA 114 (230V) and can be carried out in the
sameway.
WARNING!
-14-
TECNICA 114
FIGURE F
1
2
2
2
3
2
4
2
5
2
6
1
SETTINGS:
· PROBE
· 200V/Div;
· PROBE CH2 x10;
· 1V/Div;
· 5 sec/Div.
TIME TOLLERANCES
±20%.
±
±2
CH1 x100
VERIFY THAT:
µ
· PEAK AMPLITUDE
CH1 680V 10%.
· PEAK AMPLITUDE
CH2 4.2V 0%.
Position of switch
Switch number
FIGURE G
SETTINGS:
· PROBE
· 50V/Div;
· PROBE CH2 x100;
· 5V/Div;
· 5 sec/Div.
TIME TOLLERANCES
±20%.
· REVERSE
AMPLITUDE CH1
AND CH2 DOES NOT
EXCEED
CH1 x100
250V.
VERIFY THAT
µ
FIGURE E
position switch
number switch
1
1
2
1
3
1
4
1
5
1
6
1
SETTINGS:
· PROBE
· 200V/Div;
· PROBE CH2 x10;
· 1V/Div;
· 5 sec/Div.
TIME TOLLERANCES
±20%.
±
±
CH1 x100
VERIFY THAT:
µ
· PEAK AMPLITUDE
CH1 680V 10%.
· PEAK AMPLITUDE
CH2 2.5V 30%.

fig. 1
fig. 2A
-15-
TECNICA 114
SCREWS FASTENING
TOP COVER
POWER SUPPLY LED
CURRENT REGULATION
POTENTIOMETER
ALARM LED
SCREWS
FASTENING FRONT PANEL
SCREWS FASTENING
BACK PANEL
SCREWS
FASTENING
HANDLE
DINSE SOCKET
ILLUSTRATIONS
POWER
TRANSFORMER
SECONDARY
DISSIPATORS
POWER SUPPLY
INTERRUPTOR FAN WIRE
BOTTOM INDUCTANCE
FAN
FILTER
CAPACITORS
PRIMARY
DISSIPATORS
DIODES BRIDGE
DISSIPATOR

-16-
fig. 3
fig. 2B
DISSIPATORS
FOR DIODES
DISSIPATORS
FOR IGBT
THERMOSTAT
ST1
TECNICA 114
BUMPCONTACTS
THERMOSTAT
ST1
RHEOFORES
Q1
SCREWS
FASTENING
DINSE
SOCKETS
IGBT DISSIPATOR
SCREWS FASTENING
Q1
SECONDARY DISSIPATOR
SCREWS
FASTENING
BUMP CONTACTS
FAN
V1+,V1-
RHEOFORES
D22
C2 U3
Q1 D1 U2
R75
D34
ISO
R3, R4
D22
R55
K1
D35
R2 Q11 J8 D11 U1
C22, R22

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
-17-
Esploso macchina, Dessin appareil, Machine drawing, Explosions Zeichnung des Geräts, Diseño seccionado maquina.
TECNICA 114
1
11
4
12
5
14 6 8 16 23
1310 15
3
19
9
21
17
18
22
27
20

-18-
TECNICA 114
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!
ELENCO PEZZI DI RICAMBIO
PIECES DETACHEES
SPARE PARTS LIST
ERSATZTEILLISTE
PIEZAS DE REPUESTO
ELENCO PEZZI DI RICAMBIO
PIECES DETACHEES
SPARE PARTS LIST
ERSATZTEILLISTE
PIEZAS DE REPUESTO
ELENCO PEZZI DI RICAMBIO
PIECES DETACHEES
SPARE PARTS LIST
ERSATZTEILLISTE
PIEZAS DE REPUESTO
ELENCO PEZZI DI RICAMBIO
PIECES DETACHEES
SPARE PARTS LIST
ERSATZTEILLISTE
PIEZAS DE REPUESTO
ELENCO PEZZI DI RICAMBIO
PIECES DETACHEES
SPARE PARTS LIST
ERSATZTEILLISTE
PIEZAS DE REPUESTO
REF. REF. REF. REF. REF.
Potenziometro
Potentiometre
Potentiometer
Potentiometer
Potenciometro
Diodo
Diode
Diode
Diode
Diodo
Raddrizzatore Monofase
Redresseur Monophase
Single-phase Rectifier
Einphasiger Gleichrichter
Rectificador Monofasico
Condensatore
Condensateur
Capacitor
Kondensator
Condensador
Igbt
Igbt
Igbt
Igbt
Igbt
Rele'
Relais
Relais
Relais
Relais
Diodo
Diode
Diode
Diode
Diodo
Resistenza
Resistance
Resistor
Widerstand
Resistencia
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
Manopola Potenziometro
Poignee Pour Potentiometre
Knob For Potentiometer
Potentiometergriff
M
Termostato
Thermostat
Thermal Switch
Thermostat
Termostato
Interruttore
Interrupteur
Switch
Schalter
Interruptor
Cavo Alim.
Cable Alim.
Mains Cable
Netzkabel
Cable Alim.
Ventilatore
Ventilateur
Fan
Ventilator
Aventador
Induttanza Filtro
Inductance Filter
Filter Inductance
Filter Drossel
Induccion Filtro
Induttanza
Inductance
Inductance
Drossel
Induccion
Trasformatore Potenza
Transformateur Puissance
Power Transformer
Leistungstransformator
Transformador De Potencia
alja Por Resist.electr.variable
Frontale
Partie Frontal
Front Panel
Geraetefront
Frontal
Retro
Partie Arriere
Back Panel
Rueckseite
Trasera
Maniglia
Poignee
Handle
Handgriff
Manija
Fondo
Chassis
Bottom
Bodenteil
Base
Presa Dinse
Prise Dix
Dinse Socket
Dinse Steckdose
Enchufe Dinse
Kit Mantello
Kit Capot
Cover Lit
Deckel Kit
Kit Panel De Cobertura
Kit Scheda
Kit Fiche
Kit Board
Kit Karte
Kit Tarjeta

-19-
TECNICA 114
Official servicing centers
Repairing sheet
Date:
Inverter :
Serial number:
Company:
Technician:
model
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
cription:Des
Dirty grade
Dirty inside the machine
Description:
Rectifier bridge
Electrolytic capacitors
Relais
In-rush limiter resistance
IGBT
Snubber
Secondary diodes
Potentiometer
Others
Kind of failure Component ref.
Substitution of primary power board: yes no
Troubles evinced during repair :

TELWIN S.p.A. - Via della Tecnica, 3
36030 VILLAVERLA (Vicenza) Italy
Tel. +39 - 0445 - 858811
Fax +39 - 0445 - 858800 / 858801
E-mail: [email protected] http://www.telwin.com