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cod.

988235

TECNICA 100-140
inver ter

OPERATION
OPERATION AND
AND
WIRING
WIRING DIAGRAMS
DIAGRAMS

“trouble-free repair !”
INPUT EMC FILTER VARISTOR RECTIFIER PRECHARGE FILTER CHOPPER T.A. MAIN SECONDARY REACTANCE SECONDARY EXIT
BRIDGE TRANSFORMER CIRCUIT EMC
DIODES FILTER

FAN POWER TERTIARY VOLTAGE PRIMARY CURRENT PRIMARY CURRENT YELLOW ALARM MAXIMUM
SUPPLIES RECTIFIER DETECTOR AND DETECTOR LED CURRENT
REGULATOR

9 6 8

2
ONLY 110V MODEL

+12V POWER SEPARATOR DUTY CYCLE ADDER ALARM BLOCK POTENTIOMETER


SUPPLY UNIT TRANSFORMER PULSE
GENERATOR

9
TECNICA 100 - 140
Block diagram

DIODE TRANSFORMER
THERMOSTATIC DRIVE
CAPSULE

THERMOSTATIC GALVANIC OVERVOLTAGE


CAPSULE ON SEPARATOR PROTECTION
INDUCTANCE
TECNICA 100 - 140
The components between () belong to the secondary circuit

Block 1
EMC filter Block 9
Consists of C7, C11, C25, L1 Secondary circuit diodes
Prevents the disturbances from the inverter spreading through the Consists of D3 - 4 - 5
line and viceversa. D3: eliminate the negative part of the secondary circuit voltage.
D4 - 5: during the IGBT non-conduction period, these diodes
recirculate the output inductance current.
Block 2
Varistor Block 10
Consists of RV1 Reactance
Prevents spikes from the line with amplitude over 400V entering Consists of L1
the inverter. The reactance levels the secondary diodes output current making
it a direct current.

Block 3 Block 11
Rectifier bridge Secondary EMC filter
Consists of D4
Consists of C13, C14
Converts the alternating mains voltage into direct pulsating
Prevents the disturbances from the inverter spreading in the
voltage.
welding cables and viceversa.

Block 4 Block 12
Precharge Tertiary voltage rectifier
Consists of K1, R7 Consists of D24, D27, C24
When the inverter is switched on, the relays K1 is de-energised Rectifies and filters the voltage from the power transformer
and the capacitors C15, C16, C26, C27 are charged via R7. When tertiary winding.
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
electrolytic capacitors.
Block 13
Auxiliary power supply trigger
Consists of R42, R43
Block 5 During switch-on of the inverter, these resistors provide all the
energy necessary to power block 19 (power supply unit).
Filter
Consists of C13, C15, C16, C26, C27
Converts the pulsating voltage from the rectifying bridge into
direct voltage. Block 14
Driver
Block 6 Consists of Q4, D5, D7, Q8, D21, D23
Takes the signal from block 20 (separator transformer) and
Chopper
converts it in order to drive block 6 (chopper).
Consists of Q2, Q3, Q9, Q10
Converts the direct voltage from the filter into a square wave at
high frequency (32 khz) for driving the transformer.
Block 15
Primary current detector
Block 7 Consists of D19, R31, R33, R35
Detects the signal from block 7 (current transformer) and converts
T.A.
it in order to drive blocks 21 and 22.
Consists of T2
This current transformer measures the primary current and
transmits the information to Block 15 (duty cycle pulse generator).
Block 16
Yellow alarm led
Block 8 Consists of Q1, D3
The led comes on due to:
Main transformer
1) Cut-in of thermostatic capsule on secondary diodes.
Consists of (tr1).
2) Cut-in of thermostatic capsule on transformer.
Reduces the mains voltage, via chopper block, and galvanically
3) Cut-in due to overvoltages.
separates the primary from the secondary circuit.
3
TECNICA 100 - 140
4) Short circuit on output (electrode clamp and earth cable Consists of Q5, U1B
interconnected). When an alarm is activated this transistor brings the
5) Electrode stuck to the piece to be welded. potentiometer signal to 0.2V, drastically limiting the output current.
Block 17
Secondary circuit diodes thermostat
Consists of thermostatic capsule (S2) Block 24
When the temperature of the dissipator reaches 80°C the Potentiometer
protection cuts in. Consists of R20
By turning the potentiometer clockwise the voltage on the cursor
varies from approximately 0 to 3V, thus varying the inverter output
current.
Block 18
Thermostat on power transformer Block 25
Consists of thermostatic capsule (S1)
When the temperature on the power transformer secondary circuit Galvanic separator
reaches 130°C the protection cuts in. Consists of (Iso 1)
The signal from the thermostatic capsules is galvanically
separated and sent to block 27 (overvoltage protection).

Block 19
+12V power supply unit Block 26
Consists of U3, C21
Stabilises at 12V the power supplies from block 13 (auxiliary Transformer drive
power supply trigger) and block 12 (rectified voltage from the Consists of Q6, D8, D14
power transformer). Amplifies the signal from the duty cycle shaper.

Block 20
Block 27
Separator transformer
Consists of T1 Overvoltage protection
Provides two galvanically separated signals which are then used Consists of R25, R26, R44
to power block 14. This protection cuts in if the mains voltage exceeds 260 Vac.

Block 21
Block 28
Duty cycle shaper
Consists of U2=UC3845 Maximum current
Processes the information produced by block 22 (adder), block 15 Consists of R37 (trimmer)
(primary current detector), limits the primary current to a pre-set Regulates the maximum secondary current which the inverter can
maximum value and produces a square wave at the output with deliver.
variable duty cycle.

Block 22 Block 29
Adder Fan power supply
Consists of U1 A Only 110V version
Processes the information from the primary current detector (15), Consists of D7 and U1=7312
the alarm block (23) and the potentiometer (24), producing a Rectifies and stabilises at 12 volts the voltage from block 8 which is
voltage to drive block 21. then used to power the fan.

Block 23
Alarm block

4
(14) (6) (7) (20) (4) (26) (3)
Driver Chopper T.A. Separator Precharge Transformer Rectifier bridge
transformer drive

(2)
Varistor

(22)
Adder

(23)
Alarm block

(21)
Duty cycle
shaper

5
(24)
Potentiometer
(16)
Yellow alarm
led

(28)
Corrente
massima
TECNICA 100 - 140
Illustrated references

(1) (14) (6) (5) (27)


Block 27
(13) (15) (19)
EMC filter Driver Chopper Filter Overvoltage Auxiliary power Primary +12V power
protection supply trigger current supply unit
detector
Primary circuit
TECNICA 100 - 140
Secondary circuit

(10) (8)
Reactance Main transformer

(11)
Secondary
EMC filter

(17) (25) (18)


Secondary Galvanic Thermostat on
circuit diodes separator power
thermostat transformer

(9)
Secondary circuit diodes

6
7
General wiring diagram

ONLY
115-230V
TECNICA 100 - 140

MODEL
Primary circuit Secondary circuit

ONLY 230V MODEL ONLY 115-230V MODEL


TABELLA MONTAGGIO CONDENSATORI E JUMPER
VERS. 140 : C15,16,26 470u400V; JP3 ON
VERS. 100 : C15,16 470u400V; JP1,JP3 ON
VERS. 100 BITENS. : C15,16,26,27 1000u250V; JP2,JP4 ON

R7
REL 220R 7W ATE CS

K1
VBUS+
R8
C16 20R 9W F
RELE 18V 16A 1000u250V H5 TA+
Q3 Q2
IGBT HEATSINK HGTG20N60B3 HGTG20N60B3 D2
J2 H4
D4 MUR860 TA-
FASTON R11 R10
36MB800 DRH+ DRH+
ML16 R42
R C15

+
J4 6K8 5W F JP1 18R 18R C4 T2
J13 1M 0.5W 1000u250V
FORO 2.5 mmq JUMPER 4.7n 630V MKP 150320
D1 J11
ON 140 DRH- MUR860
L1 J1 J8
FASTON FORO 2.5mmq FASTON

-
FASTON
INDUCTOR JP4
J6 JUMPER

C13 PER IL TECNICA 100 SI POSSONO MONTARE DUE


FORO 2.5mmq D28
RV1 ON 100 .1u 630V MKP IGBT IRG4PC50U UNO PER RAMO
C25 J10 MUR860
V275LA40
1u 275 X2 JP2
FASTON
JUMPER
J15
J3 JP3
J12 FORO 2.5mmq JUMPER H3 R41
FASTON
ON M100 20R 9W F
C27 C26 ON 140
J7 1000u250V Q10 Q9 D29
FASTON 1000u250V IGBT HEATSINK
FORO 2.5mmq HGTG20N60B3 HGTG20N60B3 MUR860

R40 R39
R43
DRL+ DRL+
J5 6K8 5W F
18R 18R C23
FASTON 4.7n 630V MKP
C11
C7

8
J9 4n7 250V Y DRL-
4n7 250V Y VBUS-

I JUMPER JP1,JP2,JP3,JP4 SONO DUE FORI DIAM. 2mm A 5mm D27


FASTON
UNO DALL'ALTRO
BYV27-200 BYV27-200
D7 D5 H6 BYV27-200
ML8
DRH+ VCC
LM7812
1 3
R12 IN OUT J14
R17
Q4 390R
BC327 D12 TH 1

G
N
D
C24 C21 2
120R 18V0.5W 3
R16 U3 C20
470R 1000u40V 100u25V .1u 4
2 5
D24
VCC 27V0.5W
PANDUIT 100-5
D
18V0.5W

C8
1u
TECNICA 100 - 140

D14 D13 DRH- D26


18V0.5W REL

BYV27-200 BYV27-200
T1
R30
1K8 0.5W
BYV27-200 BYV27-200
D8
D21 D23 C22
BYV27-200
DRL+
220u40V
D25
R24 R38 LED VERDE
118320 Q8 390R D22
BC327 18V0.5W
120R
R36
R21 Q6 470R
IRFD110
Primary circuit board wiring diagram

GATE
D15
47R
R27 18V0.5W
1K
D16 C17
BYV27-200 1u DRL-
CUR

D19 R29 R32


IPLIM
TA+

1N4148 100R 680R


D18
1N4148

R28 R35 C19 R33 R31


1K 56R 0.5W 100pCER 100R 330R
D17 SOLO SU VERS. 140 VCC
24V0.5W

TA- C10
.1u Q7
D11 D10 R23 2N2222

VCC
1N4148 4.7V0.5W 680R
R37
47K RV1CM R14 C9 7 U2
100KRV1CM PER IL 2 VCC 4
RT/CT R22
TECNICA 100 IPLIM 3 VFB 8
TRIMMER MAX ISEN VREF
1K 1u 47KRV20CM
VARI TIPI 1
COMP 6
5 OUT GATE
GND
R34 UC3845N
22K
U1A
CUR
LM358N

4
R20 D6 D9
2
POT10KPIHER R19 -
1
3

9
+
1N4148 1N4148
5.6K
PROT C101

8
R15 100p
Q5 VCC
10K
C18 C12 C14
R18 C6 C1 BC337 R9 10n .1u 2.2n
390R .1u 4.7u 4.7K
C5
.1u

VBUS+

VCC
R25
120K.5W
Control wiring diagram

R4 R13
1M 820R .5W
PROT D3
R26 D20 R2 LED GIALLO
TECNICA 100 - 140

120K.5W 1N4148 15K


R1 U1B
10K LM358N

8
5
+ 7 Q1
6 BC337
R44 - R3
10K
2.2K

4
C2 R6
.1u R5 4.7K
TH C3
5.6K
.1u

VBUS-
R4 D1

ISO1
1K BYV27-200
6
JP1 1
1 5
2
3 D2 C1
4 4 2 15V .25W 100u 40V
5 R3 R1
CNY17-3 J3
PANDUIT 100-5
8K2 .5W 8K2 .5W
FORO DIAM. 1mm

J4 TERMICO
FORO DIAM. 1mm

H1
DIODE HEATSINK

D3
OUT+

RURU10060
J1 C13
C2 D4 D5 R4 10n 250VacY
FASTON 1.5n 630V MKP

10
10K5WF
J2 J5
R5
FASTON 10R 5W IMPASTO FASTON
H7 C14
ML8 T1
XFE65 21/6/1.5 10n 250VacY
L1
U LM7812 D7
OUT-
3 1
OUT IN RURU10060 RURU10060
JP2
BYV27-200 INDUCTOR IRON

G
N
D
1
2 C12
NELLA VERS. 100 POSSONO ESSERE MONTATI:

2
PANDUIT 100-2 100u40V D3 RURU8060
D3,D4 UN SOLO DIODO RURU15060

J6
FASTON
TECNICA 100 - 140

SOLO SU TECNICA 100 BITENSIONE

ISOL. PRIMARIO SECONDARIO 3750V


Secondary circuit board wiring diagram
TECNICA 100 - 140
NOTE:

11
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36030 VILLAVERLA (Vicenza) Italy ISO
Tel. +39 - 0445 - 858811
Fax +39 - 0445 - 858800 / 858801
9001 SINCERT
Deutscher
Akkreditierungs
Rat
R

E-mail: telwin@telwin.com http://www.telwin.com


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CERTIFIED QUALITY SYSTEM


U N I E N I S O 9 0 0 1 TGA-ZQ-002/92-00