Beruflich Dokumente
Kultur Dokumente
988651
111
TECNICA
TECNICA 140.1 - 142
inver ter
TROUBLESHOOTING
AND REPAIR MANUAL
CONTENTS
PAGE
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
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
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
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
Block 4
Filter
Block 13
Block 5
Chopper
Block 14
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
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
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
Secondary diodes
TECNICA 111
Block 25
Block 18
Duty cycle maker
Block 19
Block 26
Adder
Galvanic separation
Block 20
Block 27
Alarm Block
Overvoltage safeguard
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
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
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
230V
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
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
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
TECNICA 111
REPAIR GUIDE
EQUIPMENT REQUIRED
ESSENTIAL INSTRUMENTS
1
2
3
4
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.
WARNING:
EXTRAORDINARY MAINTENANCE SHOULD BE
CARRIED OUT ONLY AND EXCLUSIVELY BY
EXPERT OR SKILLED ELECTRICALMECHANICAL PERSONNEL.
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).
6.2
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
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).
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%.
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).
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
- 14 -
TECNICA 111
ILLUSTRATIONS
FIG. 1
SCREWS
FASTENING
HANDLE
CURRENT REGULATION
POTENTIOMETER
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
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
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
REF.
REF.
TECNICA 111
Dirty grade
Dirty inside the machine
Description:
Kind of failure
Rectifier bridge
Electrolytic capacitors
Component ref.
Relais
In-rush limiter resistance
IGBT
Snubber
Secondary diodes
Potentiometer
Others
- 19 -
no