cod.

988588
i nver t er
TECHNOLOGY150-170-200-186CE 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
reparation no problem !
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TECHNOLOGY 150-170-200-186CE/GE
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BLOCK DIAGRAM
OPERATION AND WIRING DIAGRAMS
OPERATION AND WIRING DIAGRAMS
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- 3 -
ANALYSIS OFTHE BLOCK DIAGRAM
NOTE: Unless indicated otherwise, it should be assumed that
the components are assembled on the welding machine.
Consisting of: C3, R5, L1, C8, C9 .
Prevents noise fromthe machine frombeing transmitted along
the main power line and vice versa.
Consisting of: 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.
Consisting of:T1 .
The C.T. is used to measure the current circulating in the power
transformer primary and transmit the information to block 14
(primary current reader and limiter).
Consisting of: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
supply line).
Block 1
Block 2
Block 5
Block 6
Block 7
Block 8
EMCFilter
Chopper
Current transformer
Power transformer
(primary board)
Consisting of: D3, D5 (primary board).
Converts the alternating mains voltage to continuous pulsed
voltage No D3 present onTechnology 150).
Consisting of: K1, K2, R1 (primary board).
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
relays K1 and K2 are de-energised, capacitors C2, C4, C5, C6,
C7 are therefore charged via R1. When the capacitors are
charged the relay will be energised. ( No K2 present on
Technology 150).
Consisting of: C2, C4, C5, C6, C7 (primary board).
Converts the pulsed voltage arriving from the rectifier bridge
to continuous voltage ( No C7 present on Technology
150).
(primary board).
(primary board)
Consisting of: D1, D2, D3, D5(secondary board).
- D1 and D2 convert the current circulating in the transformer
to a single direction, preventing saturation of the nucleus.
: No D2 onTechnology 150).
Rectifier bridge
Pre-charge
Filter
Secondarydiodes
(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,
bypassing the power transformer (block 7).
Consisting of: L1, R1.
The inductance levels the output current from the secondary
board diodes making it practically direct. The shunt detects the
current circulating in the secondary and sends a voltage signal
toblock 16 (adder), which will process it.
InductanceandShunt
hybrid board.
block 14 (duty
cycle maker).
Block 9
Block 10
Block 11
Block 12
Block 13
Block 14
Block 15
Block 16
SecondaryEMCFilter
Flybackpower supply
IGBTDriver
Primarycurrent reader andlimiter
Dutycyclemaker
Adder
AlarmBlock
Consisting of: CY1, CY2.
Prevents noise from the power source from being transmitted
through the welding cables and vice versa.
Consisting of:T2, U2 (primary board).
Uses switching methods to transformand stabilise the voltage
obtained from block 4 (filter) and supplies auxiliary voltage to
power block 12 (driver) and the
Consisting of: U1A, U1D(primary board).
Takes the signal from block 11 (flyback power supply) and,
controlled by block 14 (duty cycle maker), makes the signal
suitable for piloting block 6 (chopper).
Consisting of: R15 (primary board).
Reads the signal fromblock 6 (current transformer) and scales
it down so it can be processed and compared in
Consisting of: U2 (hybrid board).
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-set value under all circumstances.
Consisting of: U1A, U1D(hybrid board).
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
voltage for processing by block 14 (duty cycle maker).
Consisting of: Q5, R11, R14, R17 (control board).
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
obtained fromblock 18 (current potentiometer).
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
Overvoltagesafeguard
Undervoltagesafeguard
Fan
Short circuit detector
Hot Start
Arc Force
Short circuit delay
Consisting of: U3A, R62, R68 (primary board).
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).
Consisting of: U3B, R61, R67(primary board).
If the main supply voltage falls below the minimum allowed
value this safeguard triggers (a tolerance of approx. 15% of
the power supply voltage is allowed: outside this range the
safeguard triggers).
Consisting of:V1.
Powered directly 230V by block 11 (flyback transformer) and
cools the power components.
Consisting of: U3B (hybrid board).
If the welding voltage is below 10V this circuit causes block 30
(arc force) 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
prepare the weld pool.
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
electrode fromthe piece after it has become stuck.
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
AlarmLED
Current potentiometer
Welding mode function selector
Shunt Amplifier
Maximumcurrent regulator
Secondarydiodethermostat
Inductancethermostat
Galvanic separation
Consisting of: D9 (primary board).
It is switched on by block 16 (alarms) in the event of:
1) Triggering of thermostatic capsule on inductance.
2) Triggering of thermostatic capsule on secondary diodes.
3) Triggering due toundervoltage.
4) Triggering due toovervoltage.
5) Short circuit at output (electrode holder clamp and earth
cable connected to one another or electrode stuck to piece
being welded).
Consisting of: R16 (primary board).
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
minimumtothe maximumvalue.
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).
Consisting of: R13 (primary board)
Used to regulate the maximum welding current that can be
supplied by the power source.
Consisting of: ST1
When the temperature of the secondary diode dissipator is too
high the thermostat cuts in, sending an alarmsignal to block 24
(galvanic separation). It is reset automatically when this alarm
condition is no longer present.
Consisting of: 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
condition is no longer present.
Consisting of: ISO3(primary board).
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
possible alarmevent.
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)
DIODES SECONDARY
(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
3 8
1
2
9
5
7
6
- 10 -
TECHNOLOGY 150-170-200-186CE/GE
(*)The instruments with codes can be supplied by Telwin. The sale price is available on request.
REPAIR GUIDE
REPAIR 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
MACHINEWHENIT ISPOWEREDMAYCAUSE
SERIOUS ELECTRICSHOCKDUETODIRECT
CONTACTWITHLIVEPARTS.
HVPOWERSUPPLYMODULE
THE HV POWER SUPPLY is used to ensure operation of the
switching power supply (the circuit on the primary board supplying
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
can be ordered fromTelwin.
T1=insulation transformer 230-230V 50VA(*)
D1 =rectifier bridge 36MB80 (cod. 112357)
C1 =electrolytic capacitor 470uF400VALL
(cod.112514)
R1 =resistor 10 ohm5W5%
R2 =resistor 100Kohm2W5%
F1=delayed action fuse 1.5 A Fuse holder 5X20mm
Female red and black faston
Plastic box.
The following is a list of practical rules which must be strictly
adhered toif repairs are tobe carried out correctly.
A) When handling the active electronic components, the IGBT's
and Power DIODES in particular, take elementary antistatic
precautions (use antistatic footwear or wrist straps, antistatic
working surfaces etc.).
B) To ensure the heat flow between the electronic components
and the dissipator, place a thin layer of thermo-conductive
grease (e.g. COMPOUND GREASIL MS12) between the
contact zones.
C) The power resistors (should they require replacement) should
always be soldered at least 3 mmabove the board.
D) If silicone is removed fromsome points on the boards, it should
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
reticulate before the machine is tested.
E) When the semiconductor devices are soldered the maximum
temperature limits should be respected (normally 300 Cfor no
more than 10 seconds).
F) It is essential to take the greatest care at each disassembly
and assembly stage for the various machine parts.
G) Take care to keep the small parts and other pieces that are
dismantled fromthe machine so as to be able to position them
in the reverse order when re-assembling (damaged parts
should never be omitted but should be replaced, referring to
the spare parts list given at the end of this manual).
H) The boards (repaired when necessary) and the wiring should
never be modified without prior authorisation fromTelwin.
I) For further information on machine specifications and
operation, refer tothe Instruction Manual.
J) When the machine is in operation there are
dangerously high voltages on its internal parts so do not touch
the boards when the machine is live.
Every operation should be carried out in complete
safety with the power supply cable disconnected from the mains
outlet:
- Undo the 8 screws fastening the 2 plastic covers (4 each) to the
front and back .
- Undo the 8 screws fastening the top cover to the structure
.
- Slide out the top cover by pulling gently outwards .
After completing the repairs, proceed in the reverse order to re-
assemble the cover and do not forget to insert the toothed washer
on the ground screw.
Using suitably dried compressed air, carefully clean the
components of the power source since dirt is a danger to parts
subject to high voltages and can damage the galvanic separation
between the primary and secondary.
To clean the electronic boards we advise decreasing the air
pressure toprevent damage tothe 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, if there is
still damage after cleaning replace the fan.
rheofores of IGBT's Q1, Q2, Q3, Q4;
rheofores of recirculating diodes D4, D8;
rheofores of snubber network diodes D1, D6;
GENERALREPAIRINSTRUCTIONS
TROUBLESHOOTINGANDREMEDIES
N.B.
WARNING!
WARNING!
(figure1A)
(figure1B)
(figure1B)
-
-
-

1.0 Disassemblingthemachine
2.0 Cleaningtheinsideof themachine
Fan fig. 2B
Primaryboard(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 INSULATIONTRANSFORMER CAN BE REPLACED WITH
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
rheofores of opto-couplers ISO1and ISO2;
rheofores of connectors J4 and J6;
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
secondary board.
If the primary and secondary boards are removed (with the
diaphragm), carefully clean all the parts fastened to the base, or
clean the base partially fromthe sides of the machine.
Make sure there is no mechanical deformation, dent, or damaged
and/or disconnected connector.
Make sure the power supply cable has not been damaged or
disconnected internally and that the fan works with the machine
switched on. Inspect the components and cables for signs of
burning or breaks that may endanger operation of the power
source. Check the following elements:
Probable cause:
- see main power supply switch. If the relay contacts are
stuck together or dirty, do not attempt to separate them and
clean them, just replace the relay.
Probable cause:
- mechanical shock;
- machine connected to power supply voltage much higher than
the rated value;
- broken rheophore on one or more capacitor: the remainder will
be overstressed and become damaged by overheating;
- ageing after a considerable number of working hours;
- overheating caused by thermostatic capsule failure.
Probable cause:
- discontinuation in snubber network,
- fault in driver circuit
- poorly functioning thermal contact between IGBT and
dissipator (e.g. loosened attachment screws: check),
- excessive overheating related tofaulty operation
Probable cause:
- excessive overheating related tofaulty operation.
Probable cause:
- mechanical shock.
Probable cause:
- discontinuation in snubber network;
- poorly functioning thermal contact between IGBT and
dissipator (e.g. loosened attachment screws: check);
- faulty output connection.
Check it for colour changes.
Probable cause:
overheating due to loosening of the screws connecting the shunt
tothe PCB.
Inspect the windings for colour changes.
Probable causes:
- aging after a substantial number of working hours;
- excessive overheating related tofaulty operation.
It is important to check that all the connections are in good
condition and the connectors are inserted and/or attached
correctly. To do this, take the cables between finger and thumb (as
close as possible to the fastons or connectors) and pull outwards
gently: the cables should not come away from the fastons or
connectors. N.B. If the power cables are not tight enough this could
cause dangerous overheating.
A) With the multimeter set on diode testing check the following
components (joint voltages not less than 0.2V):
- rectifier bridges D3, D5 ( );
- IGBT's Q1, Q2, Q3, Q4, (no short circuits between collector-
gate and collector-emitter ( );
Before proceeding with faultfinding, we should remind
you that during these tests the power source is powered and
therefore the operator is exposed tothe danger of electric shock.
The tests described below can be used to check the operation of
the power and control parts of the power source.
A) From the primary board, disconnect fastons CN3 (XF+) and
CN10 (XF-) for the power transformer ( ).
B) Onthe primary board disconnect the jumper on JP1.
C) Connect the HV power supply OUT (code 802403) on the
primary board as follows ( ):
- (+) Positive (clamp) to rheofore of resistor R35 towards JP1
(after removing jumper JP1);
- (-) Negative (faston) tonegative faston of diode bridge D3.
D) Set up the oscilloscope with the voltage probe x100 connected
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
make very sure that the fastons listed above are disconnected and
completely isolated fromone another.
F) Connect the power supply cable to a single phase variac with
variable output 0-300Vac.
during testing prevent contact with the metal part of
the torch because of the presence of high voltages that are
hazardous tothe operator.
A) Switch on the HV power supply (HV OUT) and make sure that
( ):
- pre-charge relays K1 and K2 close;
- the fan starts toturn for the power transformer;
Power transformer andinductanceassembly
Partsfastenedtothebase
RelaysK1, K2primaryboard fig. 3
ElectrolyticcapacitorsC2,C4,C6,C7primaryboard(fig. 3
IGBT's Q1, Q2, Q3, Q4 primary board (fig. 3)
PrimarydiodesD1, D4, D6, D8 primaryboard(fig. 3)
Mode selector switchesSW1 andSW3primaryboard
(fig. 3)
SecondarydiodesD1, D2, D3, D5 secondaryboard(fig. 4)
Shunt R1secondaryboard(fig. 6)
Power transformer andfilter inductance
3.0 Visual inspection of the machine
4.0 Checkingthepower andsignal wiring
5.0 Electrical measurements with the machine
switchedoff
6.0 Electrical measurements with the machine in
operation
( )
)
.
6.1 Preparationfor testing
6.2Scheduledtests
Secondaryboard(fig. 4):)
-
-
-
fig. 4
fig. 3
fig. 3
fig. 4
fig. 4
rheofores of secondary power diodes D1, D2, D3, D5 (N.B. not
present onTechnology 150);
thermostat ST1on secondary diode dissipator;
shunt R1.
- secondary diodes D1, D2, D3, D5 between anode and
cathode ( ). The secondary diodes can be tested without
removing the primary board, placing a prod on the secondary
diode dissipator and the other in sequence on the 2 power
transformer output terminals.
B) With the multimeter in ohm mode check the following
components:
- resistor R1: 47 ohm(precharge ).
- resistors R2, R6: 10 ohm(primary snubber ).
- resistor R1: 10 ohm(secondary snubber ).
- thermostat continuity test on inductance and secondary
dissipator: disconnect connector J2 from the primary board
and make sure the resistance between pins 4 and 5 is approx.
0ohm( ).
E) Position the current potentiometer R16 on maximum (turn
clockwise as far as it will go) and switch SW1 to SOFT(as far down
as it will go);
Current potentiometer R16(fig. 3)
Probable cause:
- mechanical shock.
- 12 -
TECHNOLOGY 150-170-200-186CE/GE
- yellowled alarmis turn off.
Make sure the waveform shown on the oscilloscope
resembles .
if there is no signal it may be necessary to replace the
integrated circuit U2 or IGBTQ10 on the primary board ( ).
C) Set up the multimeter in volt mode and make sure the primary
board has the following voltages: ( ):
- between the cathode of diode D32 (+) and the negative of diode
bridge D5 (-): equal to+15Vdc 3%;
- between pin 3 (+) and the dissipator (-) of U4: equal to +12Vdc
5%;
- between pin 3 (+) and pin 1 (-) of U6: equal to-12Vdc 5%;
- between pin 8 (+) and pin 7 (-) of ISO1: equal to+26Vdc 5%;
- between pin 8 (+) and pin 7 (-) of ISO2: equal to+26Vdc 5%;
D) Switch off the HVpower supply.
E) Set up the oscilloscope with the voltage probe x10 connected
between the gate (probe) and the emitter (earth) of IGBT Q4 on
the primary board ).
F) Switch on the HV power supply (HV out) and make sure the
waveformdisplayed on the oscilloscope resembles .
G) Repeat this test on Q1, Q2, Q3as well.
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 ( , in which case we recommend replacing the board).
H) Switch off the HV and replace the 2 fastons connecting the
primary board and the power transformer (CN3 and CN10).
I) Switch on the HV and the variac (initially set to 0V), close the
main power supply switch on the machine and gradually increase
the voltage generated by the variac until it reaches 26Vac.
J) Set up the oscilloscope with the voltage probe x100 connected
between the collector (probe) and the emitter (earth) of IGBT Q4
on the primary board ( ).
K) Make sure the waveform shown on the oscilloscope
resembles
L) Repeat this test on Q2as well, using the differential probe.
If the signal is not present there may be a fault in the IGBT's
( ).
M) Return the variac voltage to 0V, switch off the machine and the
HVpower supply.
N) Disconnect the HV power supply, replace jumper JP1 on the
board.
P) Increase the voltage on the variac to 230Vac and make sure
the alarmceases (yellowLEDD9 goes off).
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
circuit U3 on the primary board ( ).
If repairing the board is complicated or impossible, it should be
completely replaced.
The board is identified by a 6-digit code (printed in white on the
component side after the initialsTW).This is the reference code for
requesting a replacement: Telwin may supply boards that are
compatible but with different codes.
before inserting a new board check it carefully for
damage that may have occurred in transit. When we supply a
board it has already been tested and so if the fault is still present
after it has been replaced correctly, check the other machine
components. Unless specifically required by the procedure, never
alter the board trimmers.
If the fault is in the primary board remove it from the machine
structure as follows:
- with the machine disconnected from the main power supply
disconnect all the wiring fromthe primary board;
- cut any bands restricting the board (e.g. on the power supply
cable and primary connections);
- undo the screws fastening the front and back panels and
remove the panels fromthe machine structure;
- undo the screws fastening the primary board to the machine
structure ;
- remove the primary board by lifting it upwards.
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.
7.0Repairs, replacingtheboards
7.1Removingtheprimaryboard(fig. 3)

O) Switch the machine on again and gradually increase the

voltage generated by the variac to 115Vac 5%then make sure an
alarmis registered with yellowLEDD9 lit up.
- 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%;

VERIFY THAT
SETTINGS:
PROBE x10;
10V/Div;
10 sec/Div.
POSITIVE AMPLITUDE
IS +18V 10%;
NEGATIVE AMPLITUDE
IS -10V 10%.

VERIFY THAT
FIGURE C
FIGURE D
SETTINGS:
PROBE x100;
10V/Div;
10 sec/Div.
AMPLITUDE ON
CH1 IS 35V 20%;

VERIFY THAT
Please read the procedure for replacing the IGBT's
carefully (fig. 3).
ohm
NOTE.
WARNING!
figure3
WARNING!
The 4 IGBT's are attached to 2 different dissipators and whenever
a replacement is required, both IGBT's should be replaced.
- Unscrewthe four (4) nuts that fix the dissipator onto the card;
- 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
the dissipator;
- remove the four (4) IGBT and the two (2) diode bridges by
unwelding the reophores, then remove tin fromthe p r i n t e d
plates;
- remove dissipator fromcard.
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
short circuit on the PCB between the 1 and 3 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
preliminary tests);
- clean any irregularity or dirt from the dissipators. If the IGBT's
have burst the dissipators may have been irreversibly
damaged: in this case they should be replaced;
- apply thermo-conductive grease following the general
instructions.
- prepare the components for replacement. For the IGBT's,
bend the rheofores at 90(never bend and/or place the parts
under tension near the case).
- position the components on the dissipator with the fastening
screws, but do not tighten the screws completely
- join the dissipator/component assembly to the printed board,
inserting all the rheofores in the bump contacts and the
threaded spacers on the 4 attachment holes.
- attach the dissipators with the nuts and lock themonce and for
all in the following order:
- the nuts fastening the dissipators to the printed circuit with a
torque wrench setting of 2 Nm20%;
- the screws fastening the rectifiers to the dissipators with a
torque wrench setting of 2 Nm20%;
- the screws fastening the IGBT's to the dissipators with a
torque wrench setting of 1 Nm20%.
- 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
and emitter).
The 4 IGBT's should belong to the same selection kit
supplied byTelwin.
- remove the 4 diodes by unsoldering the rheofores and also
remove the solder fromthe bump contacts on the PCB;
- clean any irregularities or dirt from the dissipators. If the diodes
have burst the dissipator may be irreparably damaged: in such a
case it should be replaced;
- 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
wrench setting 1 Nm20%);
- 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
under load.
A) Connect the machine to the static load generator (code
802110) using cables fittedwith the appropriate dinse connectors.
B) Set up the dual trace oscilloscope with the voltage probe
CH1x100 connected between the collector (probe) and the emitter
of Q4(earth) on the primary board ( ).
C) Pass the current probe of the Hall effect transducer along the
cable connecting the power transformer at faston CN10 with the
reference arrowpointing into CN10.
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
the OUT+and OUT- dinse connections.
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
make very sure that the fastons listed above are disconnected and
completely isolated fromone another.
st rd
TESTINGTHE MACHINE
1.1 Preparationfor testing
7.2 Removingthehybridboard(fig. 3)
7.3 Removingthesecondaryboard(fig. 4)
If the fault is in the hybrid board remove it from the primary board
as follows:
with the primary board removed from the machine structure
unsolder the rheofores from the hybrid board on the soldering
side;
remove the solder fromthe bump contacts on the PCB;
remove the hybrid board fromthe primary board;
for assembly proceed in the reverse order.
If the fault is in the hybrid board we strongly advise replacing it
without further intervention.
If the fault is in the secondary board, unless the dissipator has
been damaged by a destructive explosion of the diodes, the board
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
separate the base fromthe machine structure as follows:
- with the machine disconnected fromthe main supply undo the 4
side screws (2 on the front and 2 on the back) that attach the
board tothe base;
- turn the machine upside down and undo the 2 screws fastening
the base tothe structure;
- finally remove the base fromthe structure.
Complete removal of the secondary board fromthe structure:
- undo the 4 side screws fastening the board to the machine
structure;
- remove the 3 hexagonal-head screws that fasten the shunt and
connect the power transformer;
- disconnect the wiring for the thermostatic capsule.
for assembly proceed in the reverse order.
The 4 secondary DIODES are attached to the dissipator and
whenever a replacement is made, all 4 diodes should be replaced:
make sure that resistor R1 and capacitor C1 of the snubber
are soldered correctly ( ).
-
-
-
N.B.
N.B.
Take special note of the procedure for replacing the
secondary diodes:
N.B.
fig. 3
- 14 -
TECHNOLOGY 150-170-200-186CE/GE
G) Connect the power supply cable tothe 230Vac power supply.
during testing prevent contact with the metal part of
the torch because of the presence of high voltages that are
hazardous tothe operator.
Switch on the machine, gradually increase the power supply
voltage from0Vto230Vac and make sure that:
- the pre-charge relays on the primary board close;
- the fan starts operating correctly;
- the waveform displayed on the oscilloscope resembles
and the frequency is equal to+32.5KHz 20%;

WARNING!
A) Loadless test:
Fig. E
1.2 Scheduledtests
- 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(turn anti-clockwise as far as it will go);
- switch on the main switch;
- start up on the ohmic load and make sure that:
- the waveforms displayed on the oscilloscope resemble
those in ;
- the output current is equal to +5Adc 20% and the output
voltage is equal to+20.2Vdc %.
- switch off the ohmic load and switch off the main switch.
- set up the ohmic load with the switch settings as in the table in
;
- on the front panel position the current potentiometer on approx.
80A;
- start up the ohmic load and make sure that:
- the waveforms displayed on the oscillscope resemble
those in ;
- the output current is equal to +80Adc 10%and the output
voltage is equal to+23.2.Vdc 10%.
- switch off the ohmic load and switch off the main switch.
- the ohmic load with the switch settings according to the
relevant Technology model (see tables in );
- on the front panel position the current potentiometer on
maximum(turn clockwise as far as it will go)
- start up on the ohmic load and make sure that:
- the waveforms displayed on the oscillscope resemble those in
;
- the output current is equal to +130Adc 3% and the output
voltage is equal to +25.2Vdc 5%; if the output current reading
is not 130A 3%, adjust the current using trimmer IMAX R13
on the primary board ( ).
B) Ratedloadtest:
fig. G
Fig. F
C) Intermediate loadtest:
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.
VERIFY THAT
Number switch
Position switch
FIGURE E
6 3 2 1 4 5
3 3 3 2 2 2
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.
VERIFY THAT
FIGURE E
FIGURE F
6 3 2 1 4 5
1 0 0 0 0 0
Number 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.
VERIFY THAT
Number switch
Position switch
FIGURE E
6 3 2 1 4 5
2 2 2 2 1 0
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.
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
voltage is equal to +26.4Vdc 5%; if the output current reading
is not 160A 3%, adjust the current using trimmer IMAX R13
on the primary board ( ).
- the waveforms displayed on the oscillscope resemble those in
;
- the output current is equal to +180Adc 3% and the output
voltage is equal to +27.7Vdc 5%; if the output current reading
is not 180A 3%, adjust the current using trimmer IMAX R13
on the primary board ( ).
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
voltage is equal to +25.8Vdc 5%; if the output current reading
is not 145A 3%, adjust the current using trimmer IMAX R13
on the primary board ( ).
- switch off the ohmic load and switch off the main switch.
- 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
the secondary dissipator;
- remove the multimeter from the OUT+ and OUT- bump
contacts;
- set up the ohmic load with the switch settings according to the
relevant Technology model (see tables at point 1.2D);
- on the front panel position the current potentiometer R7 to the
maximum (turn the knob clockwise as far as it will go) and
switch on the main switch;
- activate the static load generator and make sure that the
waveforms displayed on the oscilloscope resemble those in
- 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
the current setting
.
On the front panel set switch SW1 to SOFT (as lowas it will go and
the welding current to maximum). Under the relevant load
Fig. K
fig. 3
E) Checkingthesecondary diodevoltages:
fig. L;
A)Arc Force test
Fig. G
B)Runningtime test andclosingthemachine
1.3Operational tests
- 16 -
FIGURE E
6 3 2 1 4 5
3 3 3 3 3 2
FIGURE J
TECHNOLOGY 150-170-200-186CE/GE
Number switch
Position switch
FIGURE E
FIGURE I
Number switch
Position switch
6 3 2 1 4 5
3 3 3 2 2 2
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.
VERIFY THAT
FIGURE E
6 3 2 1 4 5
3 3 3 2 2 2
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.
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.
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.
VERIFY THAT
DOES NOT
EXCEED
DOES NOT
EXCEED
conditions for the particular Technology model (see tables at 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
machine once and for all.
with the machine set up according to the instructions in the
handbook make a test weld with an electrode diam. 2.5 and the
current setting at 80A. Monitor the dynamic behaviour of the power
source, also checking for the presence of the Arc Force SW1 on
HARD(in the centre)
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 Gerts, Diseo seccionado maquina.
15
25
27
19
13
8
16
20
1 5 21 14
26 6 9 18
10 7 4 2 3 12 23 17
11 24 22
- 21 -
TECHNOLOGY 150-170-200-186CE/GE TECHNOLOGY 150-170-200-186CE/GE
ELENCO PEZZI DI RICAMBIO
PIECES DETACHEES
SPARE PARTS LIST
ERSATZTEILLISTE
PIEZAS DE REPUESTO
REF. REF. REF. REF. REF.
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
Potenziometro
Potentiometre
Potentiometer
Potentiometer
Potenciometro
Resistenza
Resistance
Resistor
Wiederstand
Resistencia
Rele'
Relais
Relais
Relais
Relais
Raddrizzatore Monofase
Redresseur Monophase
Single-phase Rectifier
Einphasiger Gleichrichter
Rectificador Monofasico
Condensatore
Condensateur
Capacitor
Kondensator
Capacitor
Condensatore
Condensateur
Capacitor
Kondensator
Condensador
Interruttore
Interrupteur
Switch
Schalter
Interruptor
Deviatore
Gareur
Switch
Schalter
Interruptor
Termostato
Thermostat
Thermal Switch
Thermostat
Cavo Alim.
Cable Alim.
Mains Cable
Netzkabe
Cable Alim.
Ventilatore
Ventilateur
Fan
Ventilator
Ventilador
Trasformatore Di Corrente Ta
Transformateur De Courant Ta
Current Transformer Ta
Stromwandler Ta
Transformador De Corriente Ta
Fibbia
Boucle
Buckle
Schnalle
Hebilla
Pressacavo
Presse Cable
Cable Bushing
Kabelhalter
Prensa Cable
Cinghia
Courroie
Belt
Gurt
Correa
Cornice
Cadre
Frame
Rahmen
Marco
Frontale
Partie Frontal
Front Panel
Geraetefront
Frontal
Retro
Partie Arriere
Back Panel
Rueckseite
Fondo
Chassis
Bottom
Bodenteil
Base
Presa Dinse
Prise Dix
Dinse Socket
Dinse Steckdose
Enchufe Dinse
Kit Diodi-igbt-resistenza
Kit Diodes-igbt-resistance
Kit Diodes-igbt-resistance
Kit Diodes-igbt-wiederstand
Kit Diodos-igbt-resistencia
Kit Scheda Secondario
Kit Fiche Secondaire
Kit Secondary Pcb
Kit Sekundaertrafokarte
Kit Tarjeta Secundario
Kit Scheda Primario
Kit Fiche Primaire
Kit Primary Pcb
Kit Primrtrafokarte
Kit Tarjeta Primario
Kit Diodo
Kit Diode
Kit Diode
Kit Diode
Kit Diodo
Kit Manopola
Kit Poignee
Knob Kit
Griff Kit
Kit Manija
Kit Trasformatore + Induttanza
Kit Tranformateur + Reactance
Kit Transformer + Reactance
Kit Trafo + Reaktanz
Kit Transformador + Reactancia
Kit Mantello
Kit Capot
Kit Cover
Kit Deckel
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
26
27
TECHNICALREPAIRCARD.
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. Pleasefill inthis sheet as accurately as possibleandsendit toTelwin. Thank youinadvancefor your co-operation!
- 22 -
TECHNOLOGY 150-170-200-186CE/GE
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 circuit board: yes no
Substitution of primary control board: yes no
Troubles evinced during repair :
TELWIN S.p.A.
800 801
- Via della Tecnica, 3
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