cod.

988241

TECHNOLOGY TIG 145-165-200

inver ter

GENERATOR
GENERATOR OPERATION
OPERATION
AND
AND WIRING
WIRING DIAGRAMS
DIAGRAMS

trouble - free repair

TECHNOLOGY 145-165-200

Block diagram
EMC FILTER

VARISTOR

RECTIFIER
BRIDGE

PRECHARGE

FILTER

CHOPPER

T.A.

MAIN
TRANSFORMER

SECONDARY
CIRCUIT
DIODES

REACTANCE
SHUNT

SECONDARY
EMC
FILTER

10

11

12

DRIVER

PRIMARY CURRENT
DETECTOR AND
REGULATOR

SHUNT
AMPLIFIER

POWER SUPPLY
UNIT

OVERVOLTAGE
PROTECTION

13

19
ALARM BLOCK

UNDERVOLTAGE
PROTECTION

17

14
DIODE
THERMOSTATIC
CAPSULE

DUTY CYCLE
PULSE
GENERATOR

18
ADDER

28

21
HOT START

15

25

THERMOSTATIC
CAPSULE ON
INDUCTANCE

DUTY CYCLE
LIMITER

16
AUXILIARY
POWER
SUPPLIES

20
MAXIMUM
OUTPUT
CURRENT
REGULATOR

22
SHORT
CIRCUIT
DETECTOR

FORCED ARC

29

23
POTENTIOMETER

ALH = +28
ALL = +28
ALP = +12
ALM = -12

30

26
SHORT
CIRCUIT
SWITCH-OFF

24

The components between () belong to the controle module SMD

27

electrolytic capacitors.

Block 1

Block 5

EMC filter

Filter

Consists of C32, C39, C40, L1, R50.

Prevents the disturbances from the inverter spreading through the
line and viceversa.

Consists of C33, C34, C35, C36, C37.

Converts the pulsating voltage from the rectifying bridge into
direct voltage.

Block 6

Block 2

Chopper

Varistor

Consists of Q6, Q7, Q8, Q9.

Converts the direct voltage from the filter into a square wave at
high frequency (32 khz) for driving the transformer.

Consists of RV1
Prevents spikes from the line with amplitude over 400V entering
the inverter.

Block 7

Block 3

T.A.

Rectifier bridge

Consists of T1.
This current transformer measures the primary current and
transmits the information to Block 18 (duty cycle pulse generator).

Consists of D19, D22.

Converts the alternating mains voltage into direct pulsating
voltage.

Block 4

Block 8
Primary current detector and regulator

Precharge
Consists of K1, K2, R34.
When the inverter is switched on, the relays K1 and K2 are deenergised and the capacitors C33-C37 are charged via R37.
When the capacitors are charged, the relays are energised.
This block prevents the formation of high transient currents which
could damage the mains switch, the rectifier bridges and the

Consists of:
(D1, R2, R55, R56, R57), R44.
Detects and limits in amplitude the signal from Block 7; via R44 the
maximum permitted primary current is regulated.
2

TECHNOLOGY 145-165-200
3. Undervoltage at output
4. Overvoltage at output
5. Short circuit at output for more than 1.5 seconds (Antistiking
function).

Block 9
Main transformer
Consists of (tr1).
Reduces the mains voltage, via chopper block, from 320V to
100V and galvanically separates the primary from the secondary
circuit.

Block 18
Duty cycle pulse generator
Consists of: (U2 = UC 3842).
Processes the information produced by Block 25 (adder), by Block
7, 8 (measurement of primary current), by Block 17 (alarms) and
produces a square wave at the output with variable duty cycle
(from 0 to 47%).

Block 10
Secondary circuit diodes
Consists of D1 - 2 - 3 - 4 - 5
D1 - 2: eliminate the negative part of the secondary circuit voltage.
D3 - 4 - 5: during the IGBT non-conduction period, these diodes
recirculate the output inductance current.

Block 19
Driver
Consists of: Iso 4, Iso 5, Q1, Q2, Q3, Q4.
Galvanically separates and amplifies in current the square wave
produced by Block 18.

Block 11
Reactance, shunt

Block 20

Consists of L R2.
The reactance levels the secondary diodes output current making
it a direct current; the shunt reads this current which is then
processed by the adder block.

Shunt amplifier
Consists of: (U4).
Amplifies the signal from the shunt.

Block 12
Secondary EMC filter

Block 21

Consists of CA, CB .
Prevents the disturbances from the inverter spreading in the
welding cables and viceversa.

Maximum output current regulator

Consists of: R 42.
Permits reduction or increase in amplification of Block 20.

Block 13
Overvoltage protection

Block 22
Hot start

Consists of: U5 A, R31, R33.

If the supply voltage exceeds 265 Vac, the chopper is switched off.

Consists of: (Q2, Q3, C9).

When the electrode touches the piece for the first time (beginning
of welding), this block increases the current set by the
potentiometer in order to prepare the welding pool.

Block 14
Undervoltage protection

Block 23

Consists of U5B, R30, R32.

If the supply voltage is below 110V, the chopper is switched off.

Forced arc
Consists of: (Q6, Q7, C14).
If the arc voltage drops below 10V, this stage produces a
temporary increase in the output current.

Block 15
Diode thermostatic capsule

Block 24

Consists of: Capsule S1.

If the temperature on the diodes exceeds 70 degrees, the chopper
is switched off.

Potentiometer
Consists of: R48.
By turning the potentiometer clockwise, the voltage on the cursor
varies from 0 to 5V which corresponds proportionally to the
inverter output current.

Block 16
Thermostatic capsule on inductance

Block 25

Consists of: capsule S2.

If the temperature of the inductance exceeds 130 degrees, the
inverter is switched off.

Adder
Consists of: (U1A, U1B).
Processes the information from Blocks 20-21-22-23-24 and sends
it to the duty cycle pulse generator (Block 17).

Block 17
Alarm block
Consists of: Q10, R48, D26, (D12, D13,Q1).
Sends a lock signal to Block 18 (switches the inverter off) and
indicates that an alarm has cut in via the yellow led D26 on the
front panel.
This led comes on when:
1. The thermostatic capsule has cut in on the diodes.
2. The thermostatic capsule has cut in on the inductance.

Block 26
Short circuit detector
Consists of (U3B).
If the welding voltage is below 10V, this circuit causes the forced
arc to cut in (Block 22).
3

TECHNOLOGY 145-165-200
output or if the inverter has locked out (e.g. due to over or
undervoltage, antistiking, thermostatic capsule).

Block 27
Short circuit switch-off

Block 29

Consists of: (U3A).

When the output short circuit persists for more than 2 seconds,
this circuit switches the inverter off via Block 16.

Duty cycle limiter

Block 28
12V power supply unit

Block 30
Auxiliary power supplies

Limits the machine duty cycle during no-load operation.

Consists of R45, D15.

Provides an output voltage of 12V which is present even when the
inverter is not working (e.g. cut-in of thermostatic capsule) and
enables Block 25 to detect whether there is a short circuit at the

In order to reduce the dimensions and weight of the inverter, a

switching power supply unit has been used with an operating
principle similar to that of the chopper.
The voltages that can be measured at its outputs are the following:

Illustrated references

(13, 14)
Over/undervoltage

(8, 17, 18, 20, 22, 23, 25, 26, 27, 28, 29)
Module SMD

(24)
Potentiometer

Switching power
supply unit

(21)
Secondary
circuit
current max regulation

(8)
(4)
(7)
Primary
Pre-charge TA
current limitation

(3)
Rectifier
bridge

(5)
Filter

(19)
Driver

(2)
Varistor

(6)
Chopper
IGBT

(1)
EMC
Filter

(6)
Chopper
IGBT

TECHNOLOGY 145-165-200
(10)

(11)

Secondary circuit diodes

Shunt

(10)

(15)

(12)

D3, 4, 5

Thermostatic
capsule

Secondary
EMC filter

(9)
Transformer

(16)
Capsule
on reactance

(11)
Reactance

CONTROL
BOARD

PRIMARY
CIRCUIT
BOARD

SECONDARY
CIRCUIT
BOARD

TECHNOLOGY 145-165-200
General wiring diagram

C39
4.7n275VacYP10

FASTONM

PE

CN7

FASTONM

1
2
3
4
5
6
7
8
9
10
11
12

PANDUIT100-12

J3

ALP12
AL0
ALM12
ALP5
RIF
POT
BLAK
CC
FUNZ
IOUT
VOUT
+5

FASTONM

CN10

FASTONM

CN3

FASTONM

CN2

C40
4.7n275VacYP10

FASTONM

CN7A

CN11

FASTONM

CN9

FASTONM 1u275VacX2P27.5

C32

R50

1M0.5W

L1

INDUCTORCOUPLED

FASTONM

CN8

H5
DISS. SU STRUTTURA

LF1

CN5
L2

FASTONM

L1

CN4

CN2
FASTONM

LF2

D19

36MB80A

REL-

D22
36MB80A

V275LA40

RV1

CN1
FASTONM

MAX

47KRV20CM
R42

REL+

ALM12

1
2
3
4
5

R43
POT10KPIHERPC16

C36

27R

R37

27R

R36

C35

OUTOUT+
SH+
THTH+

DRL-

DRL+

470RV20CM

R44

IPLIM

TA-

DR+
DR-

TA+

PPR+

10R

R51

27R

R41

27R

R40

470u400VSNAPIN3550
470u400VSNAPIN3550

C33

ALP5
ALP12

Q6

+5

SW1

RIF
POT
BLAK
TMAX1
TMAX2
IPLIM1
IPLIM2
CC
FUNZ
IOUT
VOUT

ALP12

Q8

470u400VSNAPIN3550
C34
470u400VSNAPIN3550

DRH-

DRH+

PANDUIT100-5

J1

JP2
JUMPER
TIG/MMA

AL0

.22u630VMKPP27.5

C37

RELE18V16A

K2

RELE18V16A

K1

220R5W

R34

SWITCH102

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

J2

Q9

HGTG30N60C3

R35
20R25W

C41

R45
120K

BLAK

VBUS-

C42
10n

10K

R48

2.2n630VMKPP10

C38

D20
RURP1560

VBUS+

ELBOMEC ML73/38

H9

RURP1560

D25

R38
20R5W

ALIMON

JUMPER

JP1

XF+

XF-

R49
2K2

ALP12
R46
1K0.5W

Q10
BC337

D26
LEDGIALLO

SECONDARIO

PRIMARIO

FASTONM

CN6

FASTONM

CN3

TA150320

T1

IGBT: IRG4PC4OU version 145

Relay K2 only version 165-200
Bridge D19 only version 165-200
C36 only version 165-200

10n630VMKPP15

D23
RURP880

ELBOMEC ML73/38

H7

D21
RURP1560

10n630VMKPP15

C31

D18
RURP880

CONNETTORE SCHEDA CONTROLLO

D24
RURP880

R39
20R25W

D17
RURP880

DISS. SU STRUTTURA

H8

Q7

HGTG30N60C3

DISS. SU STRUTTURA

H4

TA-

TA+

TECHNOLOGY 145-165-200

Primary circuit board wiring diagram

DR-

DR+

R3
220

C4
470pCERP5

C1
470pCERP5

R8
3K9

R2
3K9
3

8
3

ISO5
HCPL3101

ISO4
HCPL3101

ALL-

ALL+

ALH-

ALH+

C5
.1u

C2
.1u

R10
2R2

R5
2R2

Q4
BC327

Q3
BC337

Q2
BC327

Q1
BC337

C3

C6
2.2u25VTANT.

D6
10V

R9
2K2

4R7

R7

2.2u25VTANT.

D3
10V

R4
2K2

4R7

R1

R11
1K

R6
1K

D5
18V

D4
18V

D2
18V

D1
18V

DRL-

DRL+

DRH-

DRH+

TECHNOLOGY 145-165-200
Driver wiring diagram

VBUS-

VBUS+

R26

R30
22K1%

C30
1uMKTP5

270K0.5W

R27

220K0.5W

47K

R20

R32
15K1%

R17
4.3K1%

22K1%

R15

1K 1%

R31

C18
.1u

C13
47n

R33
27K 1%

R22
4K7

R24
43K1%

R19
150K

470pCERP5

C14

100u 50V

C10

1N4148

D10

OVLO

UVLO

C25
.1u

C20
1n63Vp5

8
4

6
1

LM393

U5B

LM393

U5A

UC3842AN

VREF
RT/CT

OUT
COMP

U1

C12
.1u

R29
1K5

3
ISEN 2
VFB 7
VCC

GND

R13
47K0.5W

R12
47K0.5W

R28
390R

R18
1K

CAPSULA SECONDARIO

JUMPER

JP3

NA
13

CNY17

ISO3

Q5
IRFBE30

NP
88

R25
1R2

BYV27-200

D14

D11
18V

R14
10K5WF

C24
22u25V

R28 :MONTARE SOLO SU 114185 ( 145 )

REL-

REL+

C19
470pCERP5

1K

R21

22R

R16

H1
ELBOMEC ML26AA

4.7n630VMKPP10

C11

D9
BA159

NSB
7

NS13

NS+
13

ND2
23

ND1
23

C15

10u50V

C9

10u50V

C7

PPR+

NON MONTATO SU MMA

C22

1N4004

D15

IN

ELBOMEC ML26AA

H3

OUT

C16
4.7u25V

4.7u25V

U4
LM7805CT

OUT

OUT

C27
10u50V

C23
.1u

C17
.1u

SECONDARIO

PRIMARIO

ALM12

AL0

ALP12

C29
.1u

ALP5

ISOLAMENTO 3750V

R 28 only version 145

C28
.1u

LM7912CT
U3

IN

IN

H2

ELBOMEC ML26AA
U2
LM7812CT

ALL-

ALL+

ALH-

ALH+

SOLO PER LOGICA O MICRO

C26
470u25V

BYV27-200

D16

BYV27-200

D13

47u25V

C21

470u25V

BYV27-200

D12

BYV27-200

D8

BYV27-200

G
N
D
2
1
G
N
D

C8
.22u630VMKPP27.5

8
4
8
4

G
N
D

D7

TECHNOLOGY 145-165-200

Switching auxiliary power supply unit wiring diagram

OUT-

C4

1K

R40

1N4004

D15

R52
82K

100K

R49

R58
1K

C16

1nCER

1nCER

OUT+

SH+

TA-

R1
1K

C21
10n

330R

R45

100R

R41

C15
.1uCER

D3
9V1

D18
15V

D17
15V

FUNZ

.1uCER

C6

POT

15K

R50

C18
.1uCER

C24
22p

IOUT

1N4148

C19
10n

R43
22K

D14

R25
10K

12

13

10

C23
.1uCER

+VCC

10K

R39

C17
.1uCER

U1D
LM324D
14

6K8

+VCC

U1C
LM324D

R24

CC

-VCC

IPLIM1

R57
39R

R10
100K

AMPLI
SHUNT

R56
39R

TMAX2

R55
39R

U4
LM308D

TMAX1

C11
100pCER

-VCC

-VCC

+VCC

R36
12K

R2

39R

POT
CORR.

4
8

7
1

1
1

1
1

VOUT

+5

2K2

R30

START

+5

R53
2K2

R44
5K1

Q7
BC337

R37
3K3

10K

R26

2K2

R13

RIF

1N4148

10

11

+VCC

C14
10u16V

C9
10u16V

R18
180K

Q6
BS170

CC

LM339D

13

LM324D

U1B

START

R54
3K3

+VCC

START

ARCFORCE

COMP.CORTO

U3D

COMP.
START

LM339D

U3B

1N4148

D7

C20
.1uCER

R16
47K

Q3
BC337

R22
3K3

4K7

R6

R34
22K
D11

+VCC

3
1
2

4
1
1

1K

R32

1N4148

D9

2K2

R14

R46
3K3

1N4148

D16

3
-

C13
.22u

4K7

R33

47K

R51

1nCER

D4

R9
22K

Q5
BC337

SPEGNIMENTO
CC

2K2

R31

4K7

R19

HOTSTART

Q2
BS170

IOUT

1N4148

D6

C7

R8
4K7

1nCER

R3
4K7

C8

AMPLIF.
ERRORE

4
1
1

1N4148
D2
1N4148

R28
120K

22u16V

C22

+5

R47
150K

+VCC

R35
15K

1N4148

D10

R23
10K

+VCC

1N4148

C5
4n7

U1A
LM324D

C1

C12
1nCER

33K

R12

BAT42

D19

COMP
OUT

RT/CT
VREF

14

TERMICO

FREQ

R21
1K

C3
4n7NPO

220R

R7

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

J2

DR+

STRIP SIL PRONER COMATEL

+5

OUTOUT+
SH+
THTH+
PPR+
TATA+
AL0
ALM12
ALP5
ALP12
DR+
DRRIF
POT
BLAK
TMAX1
TMAX2
IPLIM1
IPLIM2
CC
FUNZ
IOUT
VOUT

ALLARME

Q1
BC337

47KRV20CM

R5

+VCC -VCC

150

BLAK

R17
6K8

R15

+5

C2
.1uCER

The same for all versions

R48
3K3

D13
1N4148

1N4148

D12

R38
3K3

LIMIT. DUTY

+VCC

1
6

4
8

U3C
LM339D

22n

C26

UC3845AD8

U2

PROT. PRIMARIO

LM339D

U3A

TH-

22K

R11

GND

VCC
VFB
ISEN

TH+

7
2
3

PPR+

1N4148

D5

+VCC

.1uCER

100pCER

C25

IPLIM2

R4
22K

TA+

3
1
2

10
1
2

1
2
+

D1

TECHNOLOGY 145-165-200
SMD module wiring diagram

11

J4
INSERTO

XFS-

J2
INSERTO

XFS+

RURU8060

R4
10R5WF

C2
1n5 630V MKP K P15

D2

D1

D4

RURU8060

D3

HEATSINK

H1

D5

OUT+

D 2, D3 only version 165 - 200

SHUNT 1.1mOhm

R2

SH+

J3
INSERTO

J1
FASTON

TECHNOLOGY 145-165-200

Secondary circuit board wiring diagram

TELWIN S.p.A. - Via della Tecnica, 3

36030 VILLAVERLA (Vicenza) Italy
Tel. +39 - 0445 - 858811
Fax +39 - 0445 - 858800 / 858801
E-mail: telwin@telwin.com http://www.telwin.com

ISO

9001

SINCERT

Deutscher
Akkreditierungs
Rat
R

ACCREDITAMENTO ORGANISMI CERTIFICAZIONE

CERTIFIED QUALITY SYSTEM

SISTEMA QUALITA' CERTIFICATO

U N I
E N
I S O
9 0 0 1

TGA-ZQ-002/92-00