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TECNICA
TECNICA 140.1 - 142

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TROUBLESHOOTING
AND REPAIR MANUAL
CONTENTS

PAGE

OPERATION AND WIRING DIAGRAMS................ 2


Block diagram
2
Analysis of the block diagram
3
Illustrations
5
Wiring diagrams
6
REPAIR GUIDE...................................................... 9
Equipment required
9
General repair instructions
10
Troubleshooting and remedies
10
Testing the machine
13
Illustrations
15
SPARE PARTS LIST...............................................17
REPAIR SHEET......................................................19

reparation

no

problem !

INPUT

-2-

SECONDARY
DIODE
THERMOSTAT

25

24

29

POWER
TRANSFORMER
THERMOSTAT

27

OVERVOLATGE
SEFEGUARD

FAN

PRE-CHARGE

PRIMARY
EMC FILTER

12

11

26

THERMOSTATS
GALVANIC
SEPARATOR

15

11
13

28

16

TRANSFORMER
PILOT

SEPARATOR
TRANSFORMER

ALIMENTATORE
AUXILIARY POWER
FLY-BACK
SUPPLY

POWER SUPPLY
LED

14

DRIVER

AUXILIARY POWER
SUPPLY TRIGGER

VOLTAGE
RECTIFIER

18

DUTY CYCLE
MAKER

17

PRIMARY CURRENT
READER AND LIMITER

CURRENT
TRANSFORMER

CHOPPER

FILTER

RECTIFIER BRIDGE

19

ADDER

20

ALARM CLOCK

21

22

CURRENT
POTENTIOMETER

23

MAXIMUM
CURRENT ADJUST.

10

88

ALARM LED

EMC FILTER I I

INDUCTANCE

SECONDARY
DIODES

POWER
TRANSFORMER

OUTPUT

TECNICA 111

OPERATION AND WIRING DIAGRAMS

BLOCK DIAGRAM

TECNICA 111
ANALYSIS OF THE BLOCK DIAGRAM
NOTE: Unless indicated otherwise, it should be assumed that
the components are assembled on the power board.

Block 9
Inductance

Block 1

Consisting of: L1.


Levels the secondary board diodes output current making it
practically continuous.

EMC Filter
Consisting of: C1, T4, C8, C15.
Prevents noise from the machine from being transmitted
along the main power line and vice versa.

Block 10
Secondary EMC Filter

Block 2

Consisting of: C28, C33.


Prevents noise from the power source from being
transmitted through the welding cables and vice versa.

Pre-charge
Consisting of: PD1, R4.
Prevents the formation of high transitory currents that could
damage the main power switch, the rectifier bridge and the
electrolytic capacitors. When the power source is switched
on the relay PD1 is de-energised, capacitors C21, C22,
C27 are then charged by R4. When the capacitors are
charged the relay is energised.

Block 11
Voltage rectifier
Consisting of: D11,C18
Rectifies and filters the voltage from the tertiary winding of
the power transformer (block 7).

Block 3
Rectifier bridge

Block 12

Consisting of: PD1.


Converts the mains alternating voltage into continuous
pulsed voltage.

Auxiliary power supply trigger


Consisting of: R18, R35, C20
Via the resistors, the power source supplies the necessary
voltage to power block 13 (power supply).

Block 4
Filter

Block 13

Consisting of: C21, C22, C27.


Converts the pulsed voltage from the rectifier bridge into
continuous voltage. (No C22 on 230V version of Tecnica
111)

Auxiliary power supply


Consisting of: U3, C17
Stabilises the voltage at 12Vdc for the power arriving from
block 12 (auxiliary power supply trigger) and from block 11
(voltage rectifier).

Block 5
Chopper

Block 14

Consisting of: Q5, Q8.


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.

Driver
Consisting of: Q6, D19, D23, Q7, D27, D26
Picks up the signal arriving from block 15 (separator
transformer) and under the control of block 17 (transformer
pilot) adjusts it to suit piloting of block 5 (chopper).

Block 6
Current transformer

Block 15

Consisting of: T2.


The C.T. is used to measure the current circulating in the
power transformer primary and transmit the information to
block 17 (primary current reader and limiter).

Separator transformer
Consisting of: T1
Supplies two signals, which are separated galvanically from
one another, that will be sent to power block 14 (driver).

Block 7
Power transformer

Block 16

Consisting of: T3.


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).

Transformer Pilot
Consisting of: Q4, D20, D22, D24
Amplifies the signal arriving from block 18 (duty cycle
maker), needed to pilot block 15 (separator transformer).

Block 17

Block 8

Primary current reader and limiter

Secondary diodes

Consisting of: D2, R25.


Reads the signal from block 6 (current transformer) and
scales it down so it can be processed and compared in
blocks 18 and 19.

Consisting of: D33, D34 .


D33 converts the current circulating in the transformer to a
single direction, preventing saturation of the nucleus.
D34 recirculate the inductance output current (block 9)
when the IGBT's are not conducting, bypassing the power
transformer (block 7).
-3-

TECNICA 111
Block 25

Block 18
Duty cycle maker

Secondary diode thermostat

Consisting of: U1.


Processes the information from block 19 (adder) and block
17 (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.

Consisting of: ST1


When the temperature of the secondary diode dissipator
reaches a given temperature the thermostat cuts in,
sending an alarm signal to block 26 (galvanic separation). It
is reset automatically when this alarm condition is no longer
present.

Block 19

Block 26

Adder

Galvanic separation

Consisting of: U2C.


Gathers all the information from block 17 (primary current
reader and limiter), from block 20 (alarms) and from block
22 (current potentiometer), and produces a signal with a
suitable voltage for processing by block 18 (duty cycle
maker).

Consisting of: ISO1


The signal arriving from blocks 24 and 25 (power
transformer thermostat and secondary diodes) is
separated galvanically and sent to block 20 (alarms) for
detection of a possible alarm event.

Block 20

Block 27

Alarm Block

Overvoltage safeguard

Consisting of: Q3, U2A, U2B.


When an alarm is detected the power source output current
is drastically reduced by making direct adjustments to block
18 (duty cycle maker) and directly changing the reference
signal obtained from block 22 (current potentiometer).

Consisting of: R1, R5, R14, R19, R24, R29, R36, R38.
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).

Block 21

Block 28

Alarm LED

Power supply LED

Consisting of: D12.


It is switched on by block 20 (alarms) in the event of:
1) Triggering of thermostatic capsule/thermostat on power
transformer.
2) Triggering of thermostatic capsule on secondary diodes.
3) Triggering due to overvoltage.
4) Short circuit at output (electrode holder clamp and earth
cable connected to one another or electrode stuck to
piece being welded).

Consisting of: D10.


Indicates when the power source is correctly powered and
ready for use.

Block 29
Fan
Consisting of: V1.
Powered directly by block 13 (flyback transformer) and
cools the power components.

Block 22
Current potentiometer
Consisting of: 23.
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
minimum to the maximum value.

Block 23
Maximum current adjustment
Consisting of: R2.
Used to adjust the maximum cutting current to be supplied
by the power source.

Block 24
Power transformer thermostat
Consisting of: ST2.
When the temperature of the power transformer is too high,
this safeguard is triggered. It is reset automatically after the
alarm condition has ceased.

-4-

TECNICA 111
ILLUSTRATIONS
Power boad

(1)
PRIMARY EMC
FILTRE

(3)
RECTIFIER
BRIDGE

(6)
CURRENT
TRANSFORMER

(2)
PRE-CHARGE

(23)
MAX CURRENT
REGULATION

(12)
AUXILIARY
POWER
SUPPLY
TRIGGER

(18)
DUTY CYCLE
MAKER

(19)
ADDER
(20)
ALARM BLOCK

(18)
CURRENT
POTENTIOM.

(24)
POWER
SUPPLY
LED

(4)
FILTER

(17)
ALARM
LED

(9)
INDUCTANCE

(14)
DRIVER

(5)
CHOPPER

(15)
TRANSFORMER
SEPARATOR

(8)
SECONDARY
DIODES

(6)
POWER
TRANSFORMER

-5-

(10)
SECONDARY
FILTER EMC

L1

V1
Fan

S1
ON/OFF

-6-

-J4

+J4

J1

J2

N (L2)

J3

PE

J7

POWER PCB

OUT-

OUT+

230V

115V

P4

100/115V OR 230V ON L Y
MODELS WITH POWER SUPPLY CHANGE

TECNICA 111

WIRING DIAGRAMS
General wiring diagram

V1
12V dc

R 40
4K 7 0805 5%

F o ro

J7

T4
270uH 16A

-7-

D 10
V e rde 5mm

R 41
4K 7 0805 5%

-J4

+J4

C8
4n7 250V K P

Fas ton -M 6 ,3x0 ,8

J3

Fo ro

J1

C1
1u 275V M K P

Fo ro

J2

D 11
B Y G 20G

C 18
220u 50V A l l

D 36
12V 2W 5%

R 37
27R 5W 5%

R 65
N .M .

R8
1M 0W 5 5%

C15
4n7 250V K P

R V1
N .M .

1
IN

U3

C2 1
680u 400V A l l
1 8 0 0u 2 5 0 V A l l

T ECN I CA 1 1 1 11 5 V

C 20
470u 50V A l l

T ECN I CA 1 1 1 23 0 V

D8
B A V 99

Fo ro

P4

Fas ton -M 6 ,3x0 ,8

230V

Fas ton -M 6 ,3x0 ,8

115V

PD 1
G B PC3508

COND . E J UMP E R :

R 39
18K 7 0805 1%

R 64
47K 0805 1%

B Y G 20G

D9

R L1
18Vdc 36mA /250V 16A

R4
47R 8W 5%

D is s ipa to re

2 GND

H4

J P1

NO

NO

J P3

SI

NO

SI

NO

J P4

XF -

S T1

J P5

NO

SI

H2
D is s ipa to re

T3
T ra s fo P o ten za

X F+

D 12
Ga
i l lo 5mm

R 45
2K 2 0805 5%

R 35
6K 8 5W 5%

C27
100n 630V M K P

R 18
6K 8 5W 5%

C 16
100n 50V X 7R

1 8 0 0u 2 5 0 V A l l

NON MON T A TO

C2 2

C21

JP 4
Jumpe r

JP 5
Jumpe r

+12V

C 17
100u 35V A l l

OU T

LM 7812A

JP 1
Jumpe r

JP 3
Jumpe r

C22

D is s ipa to re

H1

D 32
M U R 460

D 13
M U R 460

D 21
M U R 460

R 60
10R 5W 5%

C 32
1n5 630V K P

D S E I 120 -06A

D 33

S T2

L1
10uH 85A

D 34
D S E I 120 -06A

S C H E D A PO T .T E CN .111 230 /115V -B

C34
N .M .

OU T P
OU TN

S T S _B

VA+

SO V -T

R IL -I

DC -

F15217B

D 35
M U R 460

D 14
M U R 860

CON T RO L LO E D R IV E R

C30
4n7 1000 K P

R 63
22R 9W 5%

R 46
22R 9W 5%

C25
4n7 1000 K P

S T S _A

CN 1 -1

CN 1 -6

B -Q 5

E -Q 5

B -Q 8

CN 1 -7

Q8
G
I BT

Q5
G
I BT
3

T2
T A 1 /100 15A

C28
4n7 250V K P

C33
4n7 250V K P

DC -

D 31
M U R 860

DC+

XF -

X F+

O U T+

Fo ro

OU T -

Fo ro

G RO U ND

Fo ro

TECNICA 111

Wiring diagram power board power supply

R IL - I

DC -

CN 1 -8

CN 1 -1

OU TN

+5V

D 15
18V 0W 4 5%

R 57
6K 8 5W 5%

D 25
B YG20G

OU T P

ISO 1
T LP 621

C 14
100n 50V X 7R

R 28
680R 0805 5%

R 49
1K 1206 5%

R 13
4K 7 0805 5%

R 12
10K 0805 5%

R 23
10K L in 0W 2 20%

R 21
14K 7 0805 1%

C 29
100u 35V A l l

R 50
2K 2 0805 5%

R 51
3K 3 1206 5%

R 52
3K 3 1206 5%

S T S _B

S T S _A

R 44
4K 7 0805 5%

R 43
10K 0805 5%

D2
B A V 99

D4
24V 0W 4 5%

R 11
4K 7 0805 5%

C4
4u7 16V T A N

C2
100p 50V X 7R

R6
100R 0805 5%

R 24

R 16

R 22

C 11

1n 50V N PO

C5

4V 7 0W 4 5%

R 25
27R 1W 5%

100R 0805 5%

R 15

10

R9

U 2C
LM 324

C 10
100n 50V X 7R

C3
100p 50V X 7R

680R 0805 5%

+12V

D5
B A V 99

R3
100R 0805 5%

R2
200R 1 T 0W 5 10%

C6
100n 50V X 7R

C 13
100n 50V X 7R

R 27
10K 0805 5%

D 37
4V 7 0W 4 2%

2K 2 0805 5%

D3

+12V

1K 0805 5%

R 34

CN 1 -4

1K 0805 5% 1u 25V Z 5U

Q1
B C 817

R7
10K 0805 5%

R 17
22K 0805 5%

Q3
B C 817

R 38
2K 2 0805 5%

R 36
2K 2 0805 5%

R 29
22K 1206 5%

D1
B A V 99

T e rm o s ta t i

33K 1206 5%

C19
100n 50V X 7R

D7
B AV 99

C24
1n 50V N PO

+12V

R 42
1K 0805 5%

R 19

33K 1206 5%

R 14

33K 1206 5%

4
11

R5

Isen COM P

V FB VR E F

V cc R T /C T

U1

C 12
10n 50V X 7R

D 38
B A V 99

R 10
470R 0805 5%

U C 3845A D

5 GND O U T

R 20

U 2B
LM 324

R 33
220K 0805 5%

680R 0805 5%

CN 1 -6

4
11

33K 1206 5%

1
2

+5V

CN 1 -9

CN 1 -2

CN 1 -3

CN 1 -5

C9
1n 50V N PO
C7
100n 50V X 7R

R 32

+12V

C 23
100n 50V X 7R

R 47
1K 0805 5%

R 48
47R 0805 5%

D 20
B Y G 20G

D 22
10V 0W 4 5%

Q4
IR F D 110

Q9
BC807

+12V

T1
T I 120023

100K 0805 5%

R 31

R 30
4K 7 0805 5%

D 24
10V 0W 4 5%

10K 0805 5%
D6
B AV 99

U 2A
LM 324

CN 1 -6

R 26
14K 7 0805 1%

Q2
B C 817

4
11

R1

2
3

33K 1206 5%

C31
1u 25V Z 5U

D 28
B YG20G

R 58
120R 0805 5%

D 26
B YG20G

C26
1u 25V Z 5U

D 18
B YG20G

R 56
120R 0805 5%

D 23
B YG20G

VA+
CN 1 -7

+5V

+12V

R 53
1K 0805 5%

Q6
BC807

10R 1206 5%

R 62
1K 0805 5%

Q7
BC807

R 61
10R 1206 5%

R 59
470R 0805 5%

D 27
B YG20G

R 54

14

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

T es t P o in t

D 29
18V 0W 4 5%

D 30
18V 0W 4 5%

B -Q 8

E -Q 5

18V 0W 4 5%
D 16

D 17
18V 0W 4 5%

B -Q 5

12 Fo r i P as so 2 .54mm

U 2D
LM 324

R 55
470R 0805 5%

D 19
B YG20G

13

12

CN 1 -6
CN 1 -2
CN 1 -8

CN 1 -9
CN 1 -4
CN 1 -5
CN 1 -3

4
11
2
3
2

-8-

SO V -T

TECNICA 111

Wiring diagram power board driver / control

TECNICA 111

REPAIR GUIDE
EQUIPMENT REQUIRED

ESSENTIAL INSTRUMENTS
1
2
3
4

Dual trace oscilloscope


Static load generator
Variac 0 - 300v 1500 VA
Digital multimeter

cod. 802401 (*)


cod. 802110 (*)
cod. 802402 (*)

USEFUL INSTRUMENTS
5 Unsoldering station
6 Miscellaneous tools

(*)The instruments with codes can be supplied by Telwin. The sale price is available on request.

-9-

TECNICA 111
TROUBLESHOOTING AND REMEDIES
1.0 Disassembling the machine

WARNING:
BEFORE PROCEEDING WITH REPAIRS TO THE
MACHINE READ THE INSTRUCTION MANUAL
CAREFULLY.

WARNING:
ANY CHECKS CARRIED OUT INSIDE THE
MACHINE WHEN IT IS POWERED MAY CAUSE
SERIOUS ELECTRIC SHOCK DUE TO DIRECT
CONTACT WITH LIVE PARTS.

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-mechanical personnel.
- undo the 4 screws attaching the handle to the top cover
(fig.1);
- undo the 2 screws fastening the two plastic shells to the
base: 1 screw on each side (fig.1);
- undo the 2 screws attaching the handle to the base: 1
screw on each side (fig.1);
- on the top cover undo the nut for the earth connection
(J7);
- slide out the top cover upwards (fig.1);
- undo the two screws fastening the power board to the
base.
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.

GENERAL REPAIR INSTRUCTIONS

2.0 Cleaning the inside of the machine

WARNING:
EXTRAORDINARY MAINTENANCE SHOULD BE
CARRIED OUT ONLY AND EXCLUSIVELY BY
EXPERT OR SKILLED ELECTRICALMECHANICAL PERSONNEL.

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 to prevent damage to the components.
It is therefore important to take special care when cleaning
the following parts
Fan (fig. 2A)
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.
Power board (figs. 2A and 2B):
- rheofores of IGBT's Q5, Q8;
- rheofores of recirculating diodes D14, D31;
- rheofores of secondary power diodes D33, D34, D 23;
- thermostat ST2 on power transformer;
- thermostat ST1 on secondary diode dissipator;
- opto-coupler ISO1;

The following is a list of practical rules which must be strictly


adhered to if repairs are to be 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 mm above the
board.
D) If silicone is removed from some points on the boards, it
should be re-applied.
N.B. 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 300C for 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 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
end of this manual).
H) The boards (repaired when necessary) and the wiring
should never be modified without prior authorisation
from Telwin.
I) For further information on machine specifications and
operation, refer to the Instruction Manual.
J) WARNING! 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.

3.0 Visual inspection 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:
Main power supply switch (fig. 2A)
Use the multimeter to check whether the contacts are stuck
together or open. Probable cause:
- mechanical or electric shock (e.g. bridge rectifier or
IGBT in short circuit, handling under load).
Current potentiometer R23 (fig. 3)
Probable cause:
- mechanical shock.
Relay RL1 (fig. 3)
Probable cause:
- see main power supply switch. N.B. If the relay contacts
are stuck together or dirty, do not attempt to separate
them and clean them, just replace the relay.
- 10 -

TECNICA 111
B) With the multimeter set in ohm mode check the following
components:
- resistor R4: 47ohm (pre-charge fig. 3);
- resistors R46, R63: 22ohm (primar y snubber fig. 3);
- resistor R60: 10ohm (secondary snubber fig. 3);
- continuity test for thermostat on power transformer and
for thermostat on secondary diode dissipator: clean the
resin from the bump contacts for STS(J6) and measure
the resistance over the same bump contacts, it should
be approx O Ohm (fig. 2B).

Electrolytic capacitors C21,C22 (fig. 3)


Probable cause (No C22 on 230V version of Tecnica 111):
- 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.
IGBT's Q5, Q8 (fig. 4)
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 to faulty operation.
Primary diodes D14, D31(fig. 4)
Probable cause:
- excessive overheating related to faulty operation.
Secondary diodes D33, D34 (fig. 4)
Probable cause:
- discontinuation in snubber network;
- poorly functioning thermal contact between IGBT and
dissipator (e.g. loosened attachment screws:check);
- faulty output connection.
Power transformer and filter reactance (fig. 2A)

6.0 Electrical measurements with the machine in


operation
WARNING! Before proceeding with faultfinding, 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 described below can be
used to check the operation of the power and control parts
of the power source.
6.1 Preparation for testing
A) Set up the oscilloscope with the voltage probe x10
connected between pin 2 (DRAIN) of Q4 and the earth on
the case of U3 (fig. 3).
B) Set up the multimeter in DC mode and connect the prods
to the OUT+ and OUT- bump contacts.
C) Position the potentiometer R23 on maximum (turn
clockwise as far as it will go).
D) Connect the power supply cable to a single-phase
variac with variable output 0-300 Vac.

4.0 Checking the power and signal wiring


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.
In particular, on the power board (fig.2A) it is necessary to
check the power wiring:
- the connection of the power supply cable to the fastons
at the main switch and to the earth faston (J3) on the
power board;
- the connections from the power board to the main switch
(J1, J2);
- Connections of thermostat on power transformer (ST2)
and of thermostat on secondary diode dissipator (ST1);
- Fan connections (+J4, -J4);
- Connection P4 to 230V or 115V fastons, depending on
the model.
Other checks:
Make sure that the connections to the (+) and (-) dinse
sockets are attached correctly to the power board (fig.2B).

6.2

Tests for theTECNICA 111 (230V)

A) Switch on the variac (initially set to the value 0 V), switch


off the main switch on the power source and increase the
variac voltage gradually to 230 Vac and make sure:
- the green power supply LED D10 lights up (fig. 3),
- the fan for the power transformer starts up correctly;
- the pre-charge relay K1 commutes (fig. 3);
- for voltages close to the rated power supply value
(230Vac 15%) the power source is not in alarm status
(yellow LED D12 off); N.B. if the power source stays in
alarm status permanently, there could be a fault in the
control board (in any case, proceed to make the other
tests).
B) Make sure the waveform shown on the oscilloscope
resembles fig. A.
FIGURE A
SETTINGS CH1:
PROBE x10;
10 V/Div;
5 sec/Div.
VERIFY THAT:
THE FREQUENCY IS:
52KHz 10%.
AMPLITUDE IS:
22V 10%.

5.0 Electrical measurements with the machine


switched off
A) With the multimeter set in diode testing mode check the
following components (junction voltages not less than
0.2V):
- rectifier bridge PD1 (fig. 3);
- IGBT's Q5, Q8 (absence of short circuits between
collector-gate and between emitter-collector fig. 4);
- secondary board diodes D33, D34 between anode and
cathode (fig. 4). The secondary diodes can be checked
without removing the power board: with one prod on the
secondary board dissipator diodes and the other in
sequence on the two power transformer outlets.

N.B. If this signal is absent it may be necessary to replace


component Q4 (fig. 3).
- 11 -

TECNICA 111
I) Switch the power source on again and make sure that,
following the brief start up time, the machine is not in alarm

C) Set up a multimeter in volt mode and make sure that (fig.


3):
- the voltage between pin 5 of TP and the case of U3 is
equal to +12Vdc 3%;
- the voltage between pin 12 of TP and the case of U3 is
equal to +21Vdc 3%;
- the voltage between pin 10 of TP and the case of U3 is
equal to +5Vdc 3%;
- the voltage between pin 2 of TP and the case of U3 is
equal to +3.7Vdc 5%;
the voltage on the rheofore of R37 towards L1 and the
case of U3 is equal to +12Vdc 5%.
D) Set up the dual trace oscilloscope. Connect the probe
CH1(x100) to the Q8 collector and probe CH2(x10) to the
gate, also of Q8. The earth connections are both made to
the emitter of Q8.
E) Make sure the waveform displayed on the oscilloscope
resembles fig. B.

status (the yellow alarm LED D12 is off, fig.3). N.B. If the
machine remains in alarm status (and this is not due to a fault in
the control) there could be a fault in the photocoupler ISO1 (fig.
3).

6.3 Scheduled tests for the TECNICA 111 (115V)


WARNING! Power the power source at the rated voltage of
115Vac. In this case the tests are the exactly the same as
those for the Tecnica 111 (230V) and can be carried out in
the same way.

7.0 Repairs, replacing the boards


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
initials TW). This is the reference code for requesting a
replacement: Telwin may supply boards that are compatible
but with different codes. Warning: 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.

FIGURE B
SETTINGS:
PROBE CH1 x100;
5V/Div;
PROBE CH2 x10;
10V/Div;
5 sec/Div.
TIME TOLLERANCES:
20%.
VERIFY THAT
AMPLITUDE CH1 IS
320V 10%;
POSITIVE
AMPLITUDE CH2 IS
+18V 10%;
NEGATIVE
AMPLITUDE CH2 IS
-10V 10%.

7.1 Removing the power board (fig. 2A)


If the fault is in the power board remove it from the bottom as
follows:
- with the machine disconnected from the main supply,
disconnect all the wiring connected to the board;
- remove the current adjustment knob on the front panel of
the machine ( fig. 1);
- remove any bands constraining the board (e.g. on the
power supply cable and connections to primary);
- from the welding side undo the two screws fastening the
dinse sockets to the printed circuit board (fig. 2B).
- undo the 2 screws fastening the board to the bottom (fig.
2B).
- undo the 2 screws fastening the board to the front and
back on the inside (fig. 2B).
- after removing the screws, lift the board upwards to
remove it from the bottom of the machine.
N.B. to re-assemble, proceed in the reverse order,
remembering to insert the toothed washers on the earth
screws.

F) Repeat this test on Q5 as well using the differential


probe.
N.B. if the signal is not present, there may be a fault in the
IGBT driver circuit (fig. 4).
G) Set up the dual trace oscilloscope. Connect probe CH1
(x100) to the collector of Q8 and probe CH2 (x10) to pin 1 of
TP (test point) . The earth terminals are connected together
to the emitter of Q1.
H) Make sure the waveform displayed on the oscilloscope
resembles fig.C and that the output voltage over OUT+
and OUT - is equal to +80Vdc 10%.
FIGURE C

A) Please read the procedure for replacing the IGBT's


carefully: (fig. 4).
The 2 IGBT's are attached to 2 different dissipators and
whenever a replacement is required, both IGBT's should be
replaced.
- undo the screws attaching the dissipator to the board to
replace IGBT (fig. 2B);
- undo the screws attaching the dissipator to the board to
replace IGBT(fig. 2B);
- remove the 2 IGBT's Q5,Q8 and the 2 diodes D14, D31
by unsoldering the rheofores and then clean the solder
from the printed circuit bump contacts;
- remove the 2 dissipators from the board;
- undo the screws locking the 2 IGBT's.

SETTINGS:
PROBE CH1 x 100
100V/Div;
PROBE CH2 x10;
500mV/Div;
5 sec/Div.
TOLERANCES:
FOR TIME 20%.
PEAK AMPLITUDE CH1:
320V 10%.
PEAK AMPLITUDE CH2:
500mV 10%.

- 12 -

TECNICA 111
Before making the replacement make sure the components
piloting the IGBT's are not also damaged:
- with the multimeter set in ohm mode make sure there is
no short circuit on the PCB between the 1 st and 3rd bump
contacts (between gate and emitter) corresponding to
each component;
- alternatively, resistors R54 and R61 could have burst
and/or diodes D16, D17, D29 and D30 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.
- Insert the new IGBT's between the dissipator and the
spring, taking care not to damage the component during
assembly (the spring should be inserted under pressure
on the dissipator so as to lock the component);
- place the dissipators with the new IGBT's and primary
diodes D14 and D20 (WARNING! Make sure there is
insulation between the case of diode D20 and the
dissipator) in the PCB bump contacts, placing 4 spacers
between the dissipator and the PCB (2 for each
dissipator) and fasten them down with the screws
(torque wrench setting for screws 1 Nm 20%);
- solder the terminals taking care not to let the solder run
along them;
- on the welding side cut away the protruding part of the
rheofores and check they are not shorted (between the
gate and emitter in particular).

TESTING THE MACHINE


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. WARNING! 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.
1.1 Preparation for testing.
A) Connect the power source to the static load generator
using cables fitted with the appropriate dinse connectors
(code 802110).
B) Set up the dual trace oscilloscope, connecting probe
CH1 (x100) to the collector on Q8 and probe CH2 (x10) to
pin 1 on TP (or the rheofore of R25 towards R2). The earth
terminals are connected together to the emitter, also of Q8.
C) Set up the multimeter in DC mode and connect the prods
to the OUT+ and OUT- bump contacts.
D) Connect the power supply cable to the 230Vac power
supply.
WARNING! During tests the operator must avoid contact
with the metal parts of the torch because of the presence of
dangerous, high voltage.
1.2 Scheduled tests for the TECNICA 111 (230V)
A) Intermediate load test:
- set up the static load generator with the switch settings
as in the table in fig. D;
- on the front panel position the current potentiometer at
(approx.) half way and switch on the main switch;
- activate the statico load generator and make sure that:
- the waveforms displayed on the oscilloscope
resemble those in fig. D;
- the output current is +40Adc 10%, and the output
voltage is +21.6Vdc 5%;
- deactivate the static load generator and switch off the
main switch.

B) Please read the procedure for replacing the


secondary board diodes carefully (fig. 4):
The 2 SECONDARY DIODES are attached to the same
dissipator, and when a replacement is required, all of them
should be replaced:
- undo the screws attaching the dissipator to the board, to
replace diodes D33 and D34;
- remove the 2 secondary diodes unsoldering the
rheofores and cleaning any solder from the bump
contacts on the board;
- remove the dissipator from the board;
- remove the spring locking the 2 diodes;
- clean any irregularity or dirt from the dissipator. If the
diodes have burst the dissipator may have been
irreversibly damaged: in this case it should be replaced;
- apply thermo-conductive 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 pressure
on the dissipator so as to lock the component);
- place the dissipator with the new components in the
PCB bump contacts and fasten them down with the
screws (torque wrench setting for screws 1 Nm 20%);
- solder the terminals taking care not to let the solder run
along them;
- on the soldering side cut away the protruding part of the
rheofores and check they are not shorted (between
cathode and anode);
N.B. make sure resistor (R60) and capacitor (C32) on the
snubber have been soldered to the PCB correctly (fig. 3).

FIGURE D
SETTINGS:
PROBE CH1 x100
100V/Div;
PROBE CH2 x10;
2V/Div;
5 sec/Div.
TIME TOLLERANCES
20%.
VERIFY THAT
AMPLITUDE CH1
IS 320V 10%.
AMPLITUDE CH2
IS 5V 10%.
AMPLITUDE CH2
IS 4V 10%.

1 2 3 4 5 6
1 1 1 1 1 1

- 13 -

number switch
position switch

TECNICA 111
B) Rated load test:
- set up the static load generator with the switch settings
as in the table in fig. E;
- on the front panel position the current potentiometer 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 voltage waveforms on the oscilloscope display
resemble those in fig. E;
- the output current is +85Adc 3%, and the output
voltage is +23.5Vdc 5%.
- if the output current is not +85Adc 3% , adjust the
current using the Imax trimmer R2 (Figura 2B).
- deactivate the static load generator and switch off the
main switch.

FIGURE F
SETTINGS:
PROBE CH1 x100
50V/Div;
PROBE CH2 x100;
5V/Div;
5sec/Div.
TIME TOLLERANCES
20%.
VERIFY THAT
REVERSE
AMPLITUDE CH1
AND CH2 DOES NOT
EXCEED 250V.

FIGURE E
D) Running time check and closing the machine
With the load status as in fig. E 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
positioning of the internal wiring and finally re-assemble the
machine.

SETTINGS:
PROBE CH1 x100
100V/Div;
PROBE CH2 x10;
5V/Div;
5sec/Div.
TIME TOLLERANCES
20%.
VERIFY THAT
AMPLITUDE CH1
IS 320V 10%;
AMPLITUDE CH2
IS 7V 10%.

1 2 3 4 5 6
2 2 2 2 2 2

E) Welding test
With the power source set up according to the instructions
in the handbook make a test weld at 80A (electrode
diameter 2.5 mm). Check the dynamic behaviour of the
power source.
1.3 Tests for theTECNICA 111 (115V)
WARNING! Power the power source at the rated voltage of
115Vac. In this case the tests are exactly the same as those
for the Tecnica 111 (230V) and can be carried out in the
same way.

Switch number
Position of switch

C) Checking the secondary diode voltages:


- set up the dual trace oscilloscope, connecting probe
CH1 x 100 to the anode of diode D33 and probe
CH2x100 to the anode of diode D34. Earth connections
are both made to the secondary dissipator;
- remove the multimeter from the OUT+ and OUT- bump
contacts;
- set up the static load generator with the switch settings
as in the table in fig. E;
- on the front panel position the current potentiometer
R23 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 fig. F;
- deactivate the static load generator and switch off the
main switch.

- 14 -

TECNICA 111
ILLUSTRATIONS
FIG. 1

SCREWS
FASTENING
HANDLE

CURRENT REGULATION
POTENTIOMETER

POWER SUPPLY LED

ALARM LED

SCREWS FASTENING
BACK PANEL

DINSE SOCKET

SCREWS FASTENING
TOP COVER

SCREWS
FASTENING FRONT PANEL

FIG. 2A

FIG. 2B

FILTER
POWER SUPPLY
INTERRUPTOR CAPACITORS

POWER
TRANSFORMER

BUMP
CONTACTS
THERMOSTAT
STS

BUMP
CONTACTS
RHEOFORES
FAN
RHEOFORES
Q5
+J4, -J4
D14

FAN WIRE

DIODES BRIDGE
DISSIPATOR

Q5
DISSIPATOR
SCREWS
FASTENING

Q8
DISSIPATOR
SCREWS
FASTENING

RHEOFORES
D34,D33

BOTTOM

PRIMARY
DISSIPATORS

FAN

SECONDARY INDUCTANCE
DISSIPATORS

SCREWS
FASTENING
DINSE
SOCKETS

- 15 -

SECONDARY
DISSIPATOR
SCREWS
FASTENING

RHEOFORES
Q8
RHEOFORES
D20

TECNICA 111
FIG. 3
R1

PD1

R18, R35

RL1

R2
U1 U2

U3

R23

C21
D10
D12
R46

ISO1

DISSIPATORS
FOR IGBT

THERMOSTAT
ST1
R63

DISSIPATORS
FOR DIODES

C32, R60

Q4

FIG. 4
PRIMARY
DIODE
D14

PRIMARY
DIODE
D31

DRIVER
IGBT

IGBT
Q5

D33

IGBT
Q8

- 16 -

ST1
THERMOSTAT

D34

TECNICA 111
ELENCO PEZZI DI RICAMBIO - LISTE PIECES DETACHEES
SPARE PARTS LIST - ERSATZTEILLISTE - PIEZAS DE REPUESTO
Esploso macchina, Dessin appareil, Machine drawing, Explosions Zeichnung des Gerts, Diseo seccionado maquina.

22

21
18

16

20

12

14

19

6
10
13

5
17

15

11

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 -

TECNICA 111
REF.

1
2
3
4
5
6
7
8

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
Diodo
Diode
Diode
Diode
Diodo
Condensatore
Condensateur
Capacitor
Kondensator
Condensador
Raddrizzatore
Redresseur
Rectifier
Gleichrichter
Rectificador
Manopola Potenziometro
Poignee Pour Potentiometre
Knob For Potentiometer
Potentiometergriff
Malja Por Resist.electr.variable
Interruttore
Interrupteur
Switch
Schalter
Interruptor

REF.

9
10
11
12
13
14
15
16

ELENCO PEZZI DI RICAMBIO


PIECES DETACHEES
SPARE PARTS LIST
ERSATZTEILLISTE
PIEZAS DE REPUESTO

Termostato
Thermostat
Thermal Switch
Thermostat
Termostato
Cavo Alim.
Cable Alim.
Mains Cable
Netzkabel
Cable Alim.
Ventilatore
Ventilateur
Fan
Ventilator
Ventilador
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
Fondo
Chassis
Bottom
Bodenteil
Fondo
Presa Dinse
Prise Dix
Dinse Socket
Dinse Steckdose
Enchufe Dinse

REF.

17
18
19
20
21
22

ELENCO PEZZI DI RICAMBIO


PIECES DETACHEES
SPARE PARTS LIST
ERSATZTEILLISTE
PIEZAS DE REPUESTO

REF.

ELENCO PEZZI DI RICAMBIO


PIECES DETACHEES
SPARE PARTS LIST
ERSATZTEILLISTE
PIEZAS DE REPUESTO

REF.

ELENCO PEZZI DI RICAMBIO


PIECES DETACHEES
SPARE PARTS LIST
ERSATZTEILLISTE
PIEZAS DE REPUESTO

Kit Igbt + Diodo


Kit Igbt + Diode
Kit Igbt + Diode
Kit Igbt + Diode
Kit Igbt + Diodo
Kit Mantello
Kit Capot
Cover Lit
Deckel Kit
Kit Panel De Cobertura
Kit Scheda
Kit Fiche
Kit Board
Kit Karte
Kit Tarjeta
Frontale
Partie Frontal
Front Panel
Geraetefront
Frontal
Retro
Partie Arriere
Back Panel
Rueckseite
Trasera
Maniglia
Poignee
Handle
Handgriff
Manija

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!
- 18 -

TECNICA 111

Official servicing centers


Repairing sheet
Date:
Inverter model:
Serial number:
Company:
Technician:
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
Description:

Dirty grade
Dirty inside the machine
Description:
Kind of failure

Rectifier bridge
Electrolytic capacitors

Component ref.

Substitution of primary power board: yes


Troubles evinced during repair :

Relais
In-rush limiter resistance
IGBT
Snubber
Secondary diodes
Potentiometer
Others
- 19 -

no

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