Telwin TECNICA 1400 Operating instructions

TROUBLESHOOTING
AND REPAIR MANUAL
TROUBLESHOOTING
AND REPAIR MANUAL
TECNICA 140.1 - 142
“reparation no problem !”
cod. 988401
inverter
TECNICA 1400-1600
CONTENTS PAG E
OPERATION AND ELECTRICAL DIAGRAMS................... 2
- Block diagram 2
- Analysis of block diagram 3
- Illustrations 5
- Electrical diagrams 6
REPAIR GUIDE.................................................................. 10
- Equipment required 10
- General repair instructions 11
- Troubleshooting and remedies 11
- Testing the machine 14
- Illustrations 16
SPARE PARTS LIST.......................................................... 17
REPAIR SHEET................................................................. 19
TROUBLESHOOTING
AND REPAIR MANUAL
TROUBLESHOOTING
AND REPAIR MANUAL
31/05/02

BLOCK DIAGRAM
TECNICA 1400 - 1600
- 2 -
26 25 12 13 14 19 20
24
232221
1 2 3 4 5 6 7 8 9 10 11
15 16 17 18
CONTROLLO
POWER INPUT EMC FILTER VARISTOR RECTIFIER BRIDGEPRE-CHARGE FILTER CHOPPER CURRENT
TRANSFORMER
TRANSFORMER SECONDARY
DIODES
INDUCTANCE SECONDARY EMC
FILTER
OUTPUT
FAN POWER
SUPPLY LED
FLY-BACK
POWER SUPPLY
DRIVER CURRENT READER ALARM LED MAX CURRENT
ADJUSTMENT
DUTY CYCLE
MAKER
ADDER ALARM BLOCK POTENTIOMETER
UNDERVOLTAGE
SAFEGUARD
POWER
TRANSFORMER
THERMOSTAT
GALVANIC
SEPARATOR
OVERVOLTAGE
AFEGUARD
OPERATION AND WIRING DIAGRAMSOPERATION AND WIRING DIAGRAMS
OPERATION AND WIRING DIAGRAMSOPERATION AND WIRING DIAGRAMS

- 3 -
ANALYSIS OF THE BLOCK DIAGRAM
NOTE: Unless indicated otherwise, it should be
assumed that the components are assembled on the
primaryboard.
Block 1
EMC Filter
Consistingof: C1, C5, C6, L1
Prevents noise from the machine from being
transmittedalongthemainpowerlineandviceversa.
Block 2
Varistor
Consistingof: RV1
Prevents spike noise from the mains, with amplitude
greaterthan400V,fromenteringthemachine.
Block 3
Pre-charge
Consistingof: K1, R1
Preventstheformationofhightransitorycurrentsthat
could damage the main power switch, the rectifier
bridgeandtheelectrolyticcapacitors.
Whenthepowersourceis switched on the relay K1is
de-energised, capacitors C2, C3, C4 are then
chargedbyR1. Whenthecapacitorsare charged the
relayisenergised.
Block 4
Rectifier bridge
Consistingof: D1
Converts the mains alternating voltage into
continuouspulsedvoltage.
Block 5
Filter
Consistingof: C2, C3, C4
Converts the pulsed voltage from the rectifier bridge
intocontinuousvoltage.
Block 6
Chopper
Consistingof: Q1, Q2
Converts the continuous voltage from the filter into a
high frequency square wave (65 kHz approx.)
capableofpilotingthepowertransformer.
Regulates the power according to the required
weldingcurrent/voltage.
Block 7
Currenttransformer
Consistingof: T2
The C.T. is used to measure the current circulating in
the power transformer primary and transmit the
informationtoblock14(primarycurrentreader).
TECNICA 1400 - 1600
Block 8
Powertransformer
Consistingof: T3
Reducesthe voltage converted by block6 (chopper),
adjusting voltage and current to values required for
theweldingprocedure.
Also forms galvanic separation of primary from
secondary (welding circuit from the power supply
line).
Block 9
Secondarydiodes
Consistingof: D21, D22, D23
D21 Eliminates the negative part of the secondary
voltage.
D22,D23 Recirculate the inductance output current
whentheIGBT’sarenotconducting.
Block 10
Reactance
Consistingof: L2
Levels the secondary board diodes’ output current
makingitpracticallycontinuous.
Block 11
SecondaryEMCFilter
Consistingof: C31, C32
Prevents noise from the power source from being
transmitted through the welding cables and vice
versa.
Block 12
Flybackpowersupply
Consistingof: T1, U2, U1
Uses switching methods to transform and stabilise
thevoltage obtained from block 5(filter) and supply2
voltage values of 27V that enable block 13 (driver) to
be powered correctly. It also generates a further
stabilizedvoltage of 15V that ismainly usedto power
thecontrolboard.
Block 13
Driver
Consistingof: ISO2, ISO3
Takesthesignalfromblock12(flybackpowersupply)
and, controlled by block 15 (duty cycle maker),
makes the signal suitable for piloting block 6
(chopper).
Block 14
Primarycurrentreader
Consisting of: R20, R37, R38 and part of the control
section.
Reads the signal from block 7 (current transformer)
and scales it down so it can be processed and
comparedinblocks15and16.

- 4 -
TECNICA 1400 - 1600
Block 15
Dutycyclemaker
Consistingof: U2 (controlboard) = UC 3845
Processes the information from block 16 (adder) and
block 14 (primary current reader) and produces a
square wave with variable duty cycle limiting the
primarycurrenttoamaximum pre-set value under all
circumstances.
Block 16
Adder
Consistingof: U1D (controlboard)
Gathers all the information from block 14 (primary
current reader), from block 17 (alarms) and from
block 18 (potentiometer), and produces a signal with
a suitable voltage for processing by block 15 (duty
cyclemaker).
Block 17
AlarmBlock
Consistingof: U1A, U1C (controlboard)
When an alarm is detected the machine output
current is drastically reduced by directly adjusting
and changing the reference signal obtained from
block18(potentiometer).
Block 18
Potentiometer
Consistingof: R7
Thisisusedtocreatethereferencevoltageneededto
adjust the output current: when the potentiometer is
turned the cursor voltage varies, thus varying the
currentfromtheminimumtothemaximumvalue.
Block 19
YellowLEDalarmlight
Consistingof: D26 (yellow)
Itisswitchedonbyblock17(alarms)intheeventof:
1) Triggering of thermostatic capsule on power
transformer.
2) Triggeringduetoundervoltage.
3) Triggeringduetoovervoltage.
4) Short circuit at output (electrode holder and earth
cable connected to each other or electrode stuck
topiecebeingwelded).
Block 20
Maximumcurrentadjustment
Consistingof: R32, R33, R42
Used to adjust the maximum welding current
suppliedbythepowersource.
Block 21
Powertransformerthermostat
Consistingof: ST1 thermostatic capsule.
When the temperature of the power transformer is
too high, this safeguard is triggered. It is reset
automaticallyafterthealarmconditionhasceased.
Block 22
Galvanicseparator
Consistingof: ISO1
The signal from the thermostatic capsules is
separated galvanically and sent to block 17 (alarms)
foridentificationofpossiblealarmcondition.
Block 23
Overvoltagesafeguard
Consistingof: R3, R4 andpartofthecontrolsection
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
thisrangethesafeguardtriggers).
Block 24
Undervoltagesafeguard
Consistingof: R5, R6 andpartofcontrolboard
If the main supply voltage falls below the minimum
allowed value this safeguard triggers (a tolerance of
approx.±15% of thepower supply voltageis allowed:
outsidethisrangethesafeguardtriggers).
Block 25
PowersupplyLED
Consistingof: D2
Shows that the machine is correctly powered and
readytoweld.
On machines operating exclusively at 230V it is
green.
Block 26
Fan
Cools the power components. On machines
operatingexclusivelyat230Vitispowereddirectlyby
block12 (at 12V).

ILLUSTRATIONS
TECNICA 1400 - 1600
- 5 -
1
EMC FILTER
3
RECTIFIER BRIDGE
4
PRE-CHARGE
12
FLY-BACK
TRANSFORMER
8
POWER TRANSFORMER
18
POTENTIOMETER
25
POWER
SUPPLY LED
19
ALARM LED
15 DUTY CYCLE
MAKER
22
GALVANIC
SEPARATOR
10
INDUCTANCE
21
THERMOSTATIC
CAPSULE
ON POWER
TRANSFORMER
11
SECONDARY
EMC FILTER
9
SECONDARY
DIODES
5
FILTER
6
CHOPPER
13
DRIVER
Power board

TECNICA 1400 - 1600
General wiring diagram – TECNICA 1400 – 1600
- 6 -
WIRING DIAGRAM

TECNICA 1400 - 1600
Wiring diagram for power – power supply/control board
- 7 -

TECNICA 1400 - 1600
Wiring diagram for power – power/driver board
IGBT
IGBT
- 8 -

TECNICA 1400 - 1600
- 9 -
Wiring diagram for control board

(*)The instruments with codes can be supplied by Telwin. The sale price is available on request.
TECNICA 1400 - 1600
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
USEFUL INSTRUMENTS
5 Unsoldering station
MISCELLANEOUS
6 Cutting nippers
7 Flat jaw pincers
4 2 51 3
6 7
- 10 -
REPAIR GUIDEREPAIR GUIDE
REPAIR GUIDEREPAIR GUIDE
EQUIPMENT REQUIRED

2)Cleaningtheinsideofthemachine
GENERAL REPAIR INSTRUCTIONS Using compressed air, carefully clean the components of
The following is a list of practical rules which must be the power source since dirt is a danger to parts subject to
strictlyadheredtoifrepairsaretobecarriedoutcorrectly. high voltages and can damage the galvanic separation
betweentheprimaryandsecondary.
A) When handling the active electronic components, the Itis thereforeimportantto takespecialcare whencleaning
IGBT’s and Power DIODES in particular, take thefollowingparts
elementary antistatic precautions (use antistatic
footwear or wrist straps, antistatic working surfaces
etc.).To ensure the heat flow between the electronic Fan (figure 2A): check whether dirt has damaged the
components and the dissipator, place a thin layer of correct rotation of the blades, if there is still damage after
thermo-conductive grease (e.g. COMPOUND cleaningreplacethefan.
GREASILMS12)betweenthecontactzones.
Thepowerresistors(shouldtheyrequirereplacement) Powerboard(figure2Ae2B):
should always be soldered at least 3 mm above the A) RheoforesofIGBT’sQ1,Q2,
board. B) RheoforesofrecirculatingdiodesD14,D20,
D) Ifsiliconeisremovedfromsomepointsontheboards,it C) RheoforesofsecondarypowerdiodesD21,D22,D23,
shouldbere-applied. D) Thermostaticcapsuleonpowertransformer(figure3),
NB.Useonly non-conductingneutral oroximic reticulating E) PhotocouplerISO1(figure3),
silicones (e.g. DOW CORNING 7093). Otherwise, F) Controlboard(figure3).
silicone that is placed in contact with points at different
potential (rheophores of IGBT’s, etc.) should be left to 3)Visualexaminationofthemachine
reticulatebeforethemachineistested. Make sure there is no mechanical deformation, dent, or
E) When the semi-conductor devices are soldered the damagedand/ordisconnectedconnector.
maximum temperature limits should be respected Make sure the power supply cable has not been damaged
(normally300°Cfornomorethan10seconds). or disconnected internally and that the fan works with the
F) It is essential to take the greatest care at each machineswitchedon.
disassembly and assembly stage for the various Make a visual check of components listed below for signs
machineparts. ofburningorbreakage:
G) Take care to keep the small parts and other pieces that
are dismantled from the machine so as to be able to A) Mainpowersupplyswitch(figure2A)
position them in the reverse order when re-assembling Use the multimeter to check whether the contacts are
(damagedparts shouldneverbe omittedbut shouldbe stucktogetheroropen.
replaced, referring to the spare parts list given at the Probable cause: Mechanical or electric shock (e.g.
endofthismanual). bridge rectifier or IGBT in short circuit, handling under
H) The boards (repaired when necessary) and the wiring load).
should never be modified without prior authorisation B) CurrentpotentiometerR7(figure3)
fromTelwin. Probablecause:mechanicalshock.
I) For further information on machine specifications and C) VaristorRV1(figure3)
operation,refertotheInstructionManual. Probable cause: machine connected to power supply
J) WARNING! When the machine is in operation there voltagemuchhigherthan230Vac(e.g.380Vac).
are dangerously high voltages on its internal parts so D) RelayK1(figure3)
donottouchtheboardswhenthemachineislive. Probablecause:seemainpowersupplyswitch
NB.If the relay contacts are stuck together, do not attempt
to separate them and clean them, just replace the
TROUBLESHOOTING AND relay.
E) ElectrolyticcapacitorsC2,C3(figure3)
REMEDIES Probablecause:
- mechanicalshock,
- machine connected to power supply voltage much
1)Disassemblingthemachine higherthan230Vac,
Every operation should be carried out in complete safety - broken rheophore on one or more capacitor: the
with the power supply cable disconnected from the mains remainder will be overstressed and become damaged
outlet. byoverheating,
A) Undothe10screwsfasteningthecovertothebottom:5 - agingafteraconsiderablenumberofworkinghours,
screwsoneachside(figure1). - overheatingcausedbythermostaticcapsulefailure.
B) Slideoutthecoverupwards(figure1). F) IGBT’sQ1,Q2(figure4)
Probablecause:
After completing the repairs, proceed in the reverse order - discontinuationinsnubbernetwork,
to re-assemble the cover and do not forget to insert the - faultindrivercircuit
toothedwasheronthegroundscrew.
TECNICA 1400 - 1600
- 11 -

- poorly functioning thermal contact between IGBT and transformer: clean the paint from the bump contacts of
J4 and measure the resistance between the two bump
dissipator(e.g.loosenedattachmentscrews:check), contacts,itshouldbeapprox.0ohm(figure2B).
- excessiveoverheatingrelatedtofaultyoperation.
G)PrimarydiodesD14,D20(figure4)
Probablecause:excessiveoverheatingrelatedtofaulty 6) Electrical measurements with the
operation.. machineinoperation
H) Secondary diodes D21, D22, D23 (figure 4) board The tests described below can be used to check the
removedfromthemachine) operationofthepowerandcontrolpartsofthemachine
Probablecause:
- discontinuationinsnubbernetwork, Preparationfortesting.
- poorly functioning thermal contact between IGBT and A) Set up the oscilloscope with voltage probe x100
dissipator(e.g.loosenedattachmentscrews:check), connectedbetweenpin 3ofU2(probe) andthecaseof
- faultyoutputconnection U1(ground)onthepowerboard(figure3).
I) Powertransformerandfilterreactance(figure2A). B) Position the potentiometer R7 on maximum (turn
clockwiseasfarasitwillgo).
4)Checkingpowerandsignalwiring C) Connectthemachineplugtoasingle-phasevariacwith
It is important to check that all the connections are in good variableoutput0-300Vac.
conditionand the connectors are insertedand/or attached
correctly. TestsfortheTECNICA1400
To do this, take the cables between finger and thumb (as A)Switchonthevariac(initiallysettothevalue0V),switch
close as possible to the fastons or connectors) and pull off the main switch on the machine, increase the variac
outwards gently: the cables should not come away from voltagegraduallyto230Vacandmakesure:
thefastonsorconnectors. - thepre-chargerelayK1commutes(figure3),
In particular, on the power board (figure 2A) it is - thegreenpowersupplyLEDD2lightsup(figure3),
necessarytocheckthepowerwiring: - thefan startsupcorrectly,forvoltagesclosetothe rated
A) The connection of the power supply cable to the power supply value (230Vac ±15%) the machine is not
fastonsatthemainswitchandtothefastonontheearth inalarmstatus(yellowLEDD26off).NB. Ifthemachine
board(J3), staysinalarmstatuspermanently,therecouldbeafault
B) The connections from the board to the main switch (J1, in the control board (in any case, proceed to make the
J2), othertestsasinfigure3)
In particular, on the power board (figure 2B) it is B) Use the oscilloscope to make sure that the voltage
necessarytocheckthesignalwiring: waveform between pin 3 of U2 and the ground
A) The connections of the thermostatic capsule on the resemblesthatinfigureA.
powertransformer(J4),
B) Thefanconnections(J5+,J5-),
Otherchecks:
Make sure the connectors to the dinse sockets are
attachedcorrectly(figure2B)
5) Electrical measurements with the
machineswitchedoff
With the digital multimeter set fordiode testing check the
following components (junction voltages not less than
0.2V):
A) RectifierbridgeD1(figure3).
B) IGBT’s Q1, Q2 (absence of short circuits between
collector-gateandbetweenemitter-collectorfigure4).
C) Secondary board diodes D21, D22, D23 between
anodeandcathode(figure4).
NB.Thiscanbedonewithoutremovingtheboard:withone Amplitude tolerance: ±10%
prod on the secondary board dissipator diodes and the Frequency: 65KHz ± 10%
otherinsequenceonthetwopowertransformeroutlets.
Withthedigitalmultimetersetonohmscheckthefollowing NB. If no signal is present, it may be necessary to replace
components: theintegratedcircuitU2(figure3).
A) ResistorR1:47ohm7W±5%(pre-chargefigure3).
B) Resistors R21,R27: 22ohm 13W ±5% (primary C) With the digital multimeter set on volts place the
snubberfigure3). negative prod on the ground of U1 and check the following
C) Resistor R31: 10ohm 5W ±5% (secondary snubber pointswiththepositiveprod:
figure3). - make sure that the voltage between pin 1 of U1 and the
D) Thermostatic capsule continuity test on the power
FIGURE A
TECNICA 1400 - 1600
- 12 -

Switchoffthemachineanddisconnecttheoscilloscope.
groundisequalto+18V±1V(figure3).
- make sure that the voltage between pin 3 of U1 and F) Switch the machine on again at 230Vac and make sure
the ground is equal to +15V ±0.5V (figure 3). that, following the brief start up time, the machine is not
- make sure that the voltage between pin 2 of U2 and in alarm status (the yellow alarm LED D26 is off, figure
the ground is equal to +13V ±1V (figure 3).
- make sure that the voltage between pad J5 and the 3).
ground is equal to +13V ±1V (figure 3).N.B.Ifthe machineremains inalarm status (andthis isnot
D) Set up the oscilloscope with the probe x100 connected due to a fault in the control board) there could be a fault in
between the collector (probe) and emitter (ground) of thephotocouplerISO1(figure3).
IGBTQ1.
Make sure the displayed waveform resembles that in TestsfortheTECNICA1600:
figure B.In this case the tests are just the same and can be carried
outinthesameway.
7)Repairs,replacingtheboards
If repairing the board is complicated or impossible, it
shouldbecompletelyreplaced.
Theboardisidentifiedbya6-digitcode(printedinwhiteon
the component side after the initials TW). This is the
reference code for requesting a replacement:Telwin may
supplyboardsthatarecompatiblebutwithdifferentcodes
Warning: before inserting a new board check it carefully
for damage that may have occurred in transit. When we
supplyaboardithas alreadybeen testedandsoifthefault
is still present after it has been replaced correctly, check
the other machine components. Unless specifically
requiredbytheprocedure,neveraltertheboardtrimmers.
REMOVINGTHEPOWERBOARD(figure2A)
Amplitude tolerance: ±10% - With the machine disconnected from the main supply,
Frequency: 65KHz ± 10% disconnectallthewiringconnectedtotheboard.
- Remove the current adjustment knob on the front panel
N.B. If this signal is not present, there may be a fault in ofthemachine(figure1).
the IGBT driver circuit (figure 4) or the control board - Remove any bands constraining the board (e.g.on the
(figure 3). In the latter case, we recommend replacing powersupplycableandconnectionstoprimary).
the board. - Use a screwdriver from the welding side to undo the two
screws fastening the dinse sockets to the printed circuit
E) Set up the oscilloscope with the probe x10 connected board(figure2B).
between pin 9 of the strip J6 (probe) and the case of U1 - Use a screwdriver to undo the 4 screws fastening board
(ground) (figure 3). Make sure the displayed waveform to the bottom (2 screws on the component side of the
resembles that in figure C. Make sure the output boardand2onthebottomofthemachinefigure2B).
voltagebetweenOUT+andOUT-isequalto85V±10V. - After removing the screws, lift the board upwards to
removeitfromthebottomofthemachine.
NB. To re-assemble, proceed in the reverse order,
remembering to insert the toothed washers on the
groundscrews.
A) Please read the procedure for replacing the IGBT’s
carefully:(figure4).
The 2 IGBT’s are attached to 2 different dissipators and
whenever a replacement is required, both IGBT’s should
bereplaced.
- Undothescrewsattachingthedissipatortothe board to
replaceQ1.(figure2B)
- Undothescrewsattachingthedissipatortothe board to
replaceQ2(figure2B)
- Removethe2IGBT’sQ1,Q2andthe2diodesD20,D14
by unsoldering the rheofores and then clean the solder
fromtheprintedcircuitbumpcontacts.
- Removethe2dissipatorsfromtheboard.
FIGURE B
TECNICA 1400 - 1600
- 13 -
FIGURE C
Peak amplitude 0.5V ± 20%

- Removethespringslockingthe2IGBT’s. cathodeandanode).
- Before making the replacement make sure the NB. Make sure resistor (R31) and capacitor (C30) on the
componentspilotingtheIGBT’sarenotalsodamaged: snubber have been soldered to the PCB correctly (figure
With the multimeter set on ohms make sure there is no 3).
st rd
short circuit on the PCB between the 1 and 3 bump
contacts (between gate and emitter) corresponding to C)Controlboard(figure3)
eachcomponent Whatever fault occurs in the control board, we strongly
.- Alternatively, resistors R22 and R29 could have burst recommenditsreplacementwithoutattemptsatrepair.
and/ordiodesD12,D15,D17andD19maybeunableto To remove it, cut and then unsolder the connector keeping
function at the correct Zener voltage (this should have it fixed perpendicular to the power board, replace it and
shownupinthepreliminarytests). resoldertheconnector.
- Clean any irregularity or dirt from the dissipators. If the
IGBT’s have burst the dissipators may have been TESTINGTHEMACHINE
irreversibly damaged: in this case they should be The test should be carried out on the assembled machine
replaced. beforeclosingitwiththecover.
- Apply thermoconductive grease following the general Duringtestswith themachine inoperationnever commute
instructions. the selectors or activate the noninductive load
- Insert the new IGBT’s between the dissipator and the electromagneticswitch.
spring, taking care not to damage the component
during assembly (the spring should be inserted under Preparationfortesting.
pressureonthedissipatorsoastolockthecomponent). A) Connectthemachine to thestaticloadgenerator (code
- Place the dissipators with the new IGBT’s and primary 802110) using cables supplied with the appropriate
diodes D14 and D20 (WARNING! Make sure there is dinseconnectors.
insulation between the case of diode D20 and the B) Setuptheoscilloscopewith2channels.
dissipator) in the PCB bump contacts, placing 4 C) Connect the voltage probe (CH1) x 100 between the
spacersbetweenthedissipatorandthePCB(2foreach collector(probe)andemitter(ground)ofIGBTQ1.
dissipator) and fasten them down with the screws D) Connectthevoltageprobe(CH2)x10betweenPIN9of
(torquewrenchsettingforscrews1Nm±20%). stripJ6(probe)andtheemitter.
- Solderthe terminalstakingcare notto let thesolder run E) Connectthemachineplugtothevariac.
alongthem.
- On the welding side cut away the protruding part of the TestsfortheTECNICA1400.
rheofores and check they are not shorted (between the A)Averageloadtest:
gateandemitterinparticular).- With the static load generator disconnected, switch on
the variac and the machine main switch.Gradually take
B) Please read the procedure for replacing the secondary thepower supplyvoltagefrom 0V to230Vac,makesure
boarddiodescarefully:(figure 4). the pre-load relay commutes, the fan starts operating
The 3 SECONDARY DIODES are attached to the same correctlyandthepowersupplyLEDD2lightsup.
dissipator, and when a replacement is required, all three Set up the static load generator with the switch settings
shouldbereplaced: asinthetableinfigureD,onthefrontpanelpositionthe
- Undo the screws attaching the dissipator to the board, weldingcurrentpotentiometeron60Aandswitchonthe
toreplaceD21,D22andD23. powersupply:
- Remove the 3 secondary diodes D21, D22 and D23, - Check that the voltage waveforms on the oscilloscope
unsolderingthe rheoforesandcleaning anysolder from displayresemblethoseinfigureD.
thebumpcontactsontheboard.
- Removethedissipatorfromtheboard.
- Removethespringlockingthe3diodes.
- Clean any irregularity or dirt from the dissipator. If the
diodes have burst the dissipator may have been
irreversiblydamaged:inthiscaseitshouldbereplaced.
- Apply thermoconductive grease following the general
instructions.
- Insert the new diodes between the dissipator and the
spring, taking care not to damage the component
during assembly (the screw should be inserted under
pressureonthedissipatorsoastolockthecomponent).
- Place the dissipator with the new components in the
PCB bump contacts and fasten them down with the
screws(torquewrenchsettingforscrews1Nm±20%).
- Solderthe terminalstakingcare notto let thesolder run
alongthem.
- On the welding side cut away the protruding part of the
rheofores and check they are not shorted (between
FIGURE D
0
TECNICA 1400 - 1600
Voltage at ends of load:20.5V ±5%
Current in load: 60A ±3%
- 14 -
SWITCH NUMBER
SWITCH POSITION

B) Rated load test:Set up the static load generator with the D) Runningtimecheckandclosingthemachine:
switch settings as in the table in figure E, on the front - With the load status as in figure E and the current
panel turn the welding current potentiometer clockwise adjustment potentiometer on maximum, switch on the
to maximumand switch onthe power supply. machine and leave it in operation until the thermostatic
- Check that the voltage and current waveforms on the capsulestrigger(machineinalarmstatus).
- Check the correct positioning of the internal wiring and
oscilloscopedisplayresemblethoseinfigureE. finallyre-assemblethemachine.
E)Weldingtest:
With the machine preset as given in the instruction
manual make a test weld with a current of 80A
(electrodediam. 2.5mm):check thedynamicbehaviour
ofthemachine.
TestsfortheTECNICA1600:
The tests for the Tecnica 1600 are as above and can be
carried out in the same way except for the rated load test
(see B) and the voltage check on the secondary diodes
(seeC).
NB.Ratedload:
- Set up the static load generator with the switch settings
as in the table in table 1, on the front panel turn the
welding current potentiometer clockwise as far as it will
go(maximum)andswitchonthepowersupply.
- Check that the voltage and current waveforms on the
oscilloscope display resemble those in figure E.Make
sure the current value on the static load generator is
149A±3% with a voltage of 26V± 5%.NB. Checking the
secondaryboarddiodevoltages:
Voltage at ends of load:24.8V ±5% - Set up the static load generator with the switch settings
Current in load: 120A ±3% as in table 1, on the front panel turn the welding current
potentiometer clockwise to maximum and switch on the
C)Checkingthesecondarydiodevoltages: powersupply.
- Connect 2 voltage probes x100 between the 2 outlets of - Check that the voltage waveforms on the oscilloscope
the power transformer T1 (probe) and the secondary displayresemblethoseinfigureF.
dissipator(ground).
- Connect the 2 probes to the oscilloscope and under the
load conditions given in the second table in figure E
switch on the machine and position the current
adjustment potentiometer on maximum (turn clockwise
asfarasitwillgo). Table 1
- Check that the voltage waveforms on the oscilloscope
displayresemblethoseinfigureF. WARNING!
Voltage and current measurements for the TECNICA 1400
and 1600 should be made at a main power supply voltage
ofatleast220Vac.
Main supply voltage should be measured over the main
powerswitchwiththemachineoperatingatfullpower.
FIGURE E
FIGURE F
Amplitude tolerance: ±10%
Reverse voltage peak should not exceed 150V
TECNICA 1400 - 1600
CH1 maximum amplitude 320V ± 10%
CH2 peak amplitude 8V ± 10%
- 15 -
SWITCH NUMBER
SWITCH POSITION
SWITCH NUMBER
SWITCH POSITION

FIG. 1
COVER
FASTENING
SCREWS
CURRENT
ADJUSTMENT
POTENTIOMETER
POWER BOARD
FIG. 2A
FIG. 3
FIG. 2B
FIG. 4
C2
C3 RV1 R1 U2
RELÈ K1 U1
R7
LED
D2
LED
D26
ISO 1
R27
R21
R31 E C30
DIODE BRIDGE
D14
PRIMARY DISSIPATOR
D20
IGBT Q1
SECONDARY DIODES
IGBT Q2
IGBT DRIVER
TECNICA 1400 - 1600
- 16 -
COVER
FASTENING SCREWS
POWER
SUPPLY LED
ALARM LED
DINSE SOCKETS
MAIN
SUPPLY SWITCH
MAIN
SWITCH
CONNECTIONS
FILTER
CAPACITORS
FAN WIRES FILTER
REACTANCE
POWER
TRANSFORMER
SECONDARY
DIODES
FAN
BOTTOM
IGBT
DISSIPATORS
BOARD
FASTENING SCREW
FAN BUMP
CONTACTS
(J5+, J5-)
RHEOFORES
Q2 RHEOFORES
14
BOARD
FASTENING
SCREW
IGBT Q2
DISSIPATOR
FASTENING
SCREWS
IGBT Q1
DISSIPATOR
FASTENING
SCREWS
BOARD
ATTACHMENT
SCREW
RHEOFORES D20
RHEOFORES
Q1
THERMOSTATIC
CAPSULE
BUMP
CONTACTS
J4
SECONDARY
DISSIPATOR
FASTENING
SCREW
RHEOFORES
D23, D22, D21
BOARD
ATTACHMENT
SCREW
SECONDARY
DISSIPATOR
FASTENING
SCREW
FASTENING
SCREWS
FOR DINSE
SOCKET
CONNECTORS
DIODE BRIDGE D1FLY-BACK TRANSFORMER
CONTROL BOARD
THERMOSTATIC
CAPSULE
SECONDARY
DISSIPATOR
SECONDARY
DISSIPATOR
ILLUSTRATIONS
D21 D22 D23

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.
TECNICA 1400 - 1600
13
11
15
20
25
24
7
23
19
1
26
4
12
3
810
22
18 14 5 17
9
21
16
- 17 -

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
Interruttore
Interrupteur
Switch
Schalter
Interruptor
Scheda Controllo
Platine De Control
Control Pcb
Steurungskarte
Tarjeta De Controlo
Cavo Alimentazione
Cable D'alimentation
Mains Cable
Netzkabel
Cable De Alimentacion
Ventilatore
Ventilateur
Fan
Ventilator
Ventilador
Raddrizzatore
Redresseur
Rectifier
Gleichrichter
Rectificador
Induttanza Filtro
Inductance Filter
Filter Inductance
Filter Drossel
Induccion Filtro
Induttanza
Inductance
Inductance
Drossel
Induccion
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
Trasformatore Potenza
Trasformateur Puissance
Power Transformer
Leistungstransformator
Transformador De Potencia
Pressacavo
Presse Cable
Cable Bushing
Kabelhalter
Prensa Cable
Fibbia Per Cinghia
Boucle Pour Courroie
Belt Buckle
Gurtschnalle
Hebilla Para Correa
Aggancio Per Cinghia
Accrochage Pour Courroie
Belt Hook
Gurthaken
Gancho Para Correa
Cinghia
Courroie
Belt
Gurt
Correa
Fondo
Chassis
Bottom
Bodenteil
Fondo
Mantello
Capot
Cover
Deckel
Panel De Cobertura
Presa Dinse
Prise Dix
Dinse Socket
Dinse Steckdose
Enchufe Dinse
Diodo
Diode
Diode
Diode
Diodo
Kit Igbt + Diodo
Kit Igbt + Diode
Kit Igbt + Diode
Kit Igbt + Diode
Kit Igbt + Diodo
Kit Scheda Completa
Kit Platine Complete
Kit Complete Card
Kit Komplette Karte
Kit Tarjeta Completa
Pwm Controller
Pwm Controller
Pwm Controller
Pwm Controller
Pwm Controller
Kit Manopola
Kit Poignee
Knob Kit
Griff Kit
Kit Manija
Condensatore
Condensateur
Capacitor
Kondensator
Condensador
Resistenza
Resistance
Resistor
Widerstand
Resistencia
Rele'
Relais
Relais
Relais
Relais
Trasformatore
Transformateur
Transformer
Transformator
Transformador
TECNICA 1400 - 1600
Technicalrepairsheet:
To improve our service, on completing each repair we request all Service Centres to complete the technical
repairsheetasonthenextpage,andreturnittoTelwin.
- 18 -

TECNICA 1400 - 1600
- 19 -
Official servicing centers
Repairing card
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 circuit board: yes no
Troubles evinced during repair :

CERTIFIED QUALITY SYSTEM
ISO
9001
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