Telwin TECNICA 1400 Instrucciones de funcionamiento

TROUBLESHOOTING

AND REPAIR MANUAL

TROUBLESHOOTING

AND REPAIR MANUAL

TECNICA 140.1 - 142

“reparation no problem !”

cod. 988401

inverter

TECNICA 1400-1600

CONTENTS PAG E

OPERATION AND ELECTRICAL DIAGRAMS................... 2

- Block diagram 2

- Analysis of block diagram 3

- Illustrations 5

- Electrical diagrams 6

REPAIR GUIDE.................................................................. 10

- Equipment required 10

- General repair instructions 11

- Troubleshooting and remedies 11

- Testing the machine 14

- Illustrations 16

SPARE PARTS LIST.......................................................... 17

REPAIR SHEET................................................................. 19

TROUBLESHOOTING

AND REPAIR MANUAL

TROUBLESHOOTING

AND REPAIR MANUAL

31/05/02

BLOCK DIAGRAM

TECNICA 1400 - 1600

- 2 -

26 25 12 13 14 19 20

232221

1 2 3 4 5 6 7 8 9 10 11

15 16 17 18

CONTROLLO

POWER INPUT EMC FILTER VARISTOR RECTIFIER BRIDGEPRE-CHARGE FILTER CHOPPER CURRENT

TRANSFORMER

TRANSFORMER SECONDARY

DIODES

INDUCTANCE SECONDARY EMC

FILTER

OUTPUT

FAN POWER

SUPPLY LED

FLY-BACK

POWER SUPPLY

DRIVER CURRENT READER ALARM LED MAX CURRENT

ADJUSTMENT

DUTY CYCLE

MAKER

ADDER ALARM BLOCK POTENTIOMETER

UNDERVOLTAGE

SAFEGUARD

POWER

TRANSFORMER

THERMOSTAT

GALVANIC

SEPARATOR

OVERVOLTAGE

AFEGUARD

OPERATION AND WIRING DIAGRAMSOPERATION AND WIRING DIAGRAMS

- 3 -

ANALYSIS OF THE BLOCK DIAGRAM

NOTE: Unless indicated otherwise, it should be

assumed that the components are assembled on the

primaryboard.

Block 1

EMC Filter

Consistingof: C1, C5, C6, L1

Prevents noise from the machine from being

transmittedalongthemainpowerlineandviceversa.

Block 2

Varistor

Consistingof: RV1

Prevents spike noise from the mains, with amplitude

greaterthan400V,fromenteringthemachine.

Block 3

Pre-charge

Consistingof: K1, R1

Preventstheformationofhightransitorycurrentsthat

could damage the main power switch, the rectifier

bridgeandtheelectrolyticcapacitors.

Whenthepowersourceis switched on the relay K1is

de-energised, capacitors C2, C3, C4 are then

chargedbyR1. Whenthecapacitorsare charged the

relayisenergised.

Block 4

Rectifier bridge

Consistingof: D1

Converts the mains alternating voltage into

continuouspulsedvoltage.

Block 5

Filter

Consistingof: C2, C3, C4

Converts the pulsed voltage from the rectifier bridge

intocontinuousvoltage.

Block 6

Chopper

Consistingof: Q1, Q2

Converts the continuous voltage from the filter into a

high frequency square wave (65 kHz approx.)

capableofpilotingthepowertransformer.

Regulates the power according to the required

weldingcurrent/voltage.

Block 7

Currenttransformer

Consistingof: T2

The C.T. is used to measure the current circulating in

the power transformer primary and transmit the

informationtoblock14(primarycurrentreader).

TECNICA 1400 - 1600

Block 8

Powertransformer

Consistingof: T3

Reducesthe voltage converted by block6 (chopper),

adjusting voltage and current to values required for

theweldingprocedure.

Also forms galvanic separation of primary from

secondary (welding circuit from the power supply

line).

Block 9

Secondarydiodes

Consistingof: D21, D22, D23

D21 Eliminates the negative part of the secondary

voltage.

D22,D23 Recirculate the inductance output current

whentheIGBT’sarenotconducting.

Block 10

Reactance

Consistingof: L2

Levels the secondary board diodes’ output current

makingitpracticallycontinuous.

Block 11

SecondaryEMCFilter

Consistingof: C31, C32

Prevents noise from the power source from being

transmitted through the welding cables and vice

versa.

Block 12

Flybackpowersupply

Consistingof: T1, U2, U1

Uses switching methods to transform and stabilise

thevoltage obtained from block 5(filter) and supply2

voltage values of 27V that enable block 13 (driver) to

be powered correctly. It also generates a further

stabilizedvoltage of 15V that ismainly usedto power

thecontrolboard.

Block 13

Driver

Consistingof: ISO2, ISO3

Takesthesignalfromblock12(flybackpowersupply)

and, controlled by block 15 (duty cycle maker),

makes the signal suitable for piloting block 6

(chopper).

Block 14

Primarycurrentreader

Consisting of: R20, R37, R38 and part of the control

section.

Reads the signal from block 7 (current transformer)

and scales it down so it can be processed and

comparedinblocks15and16.

- 4 -

TECNICA 1400 - 1600

Block 15

Dutycyclemaker

Consistingof: U2 (controlboard) = UC 3845

Processes the information from block 16 (adder) and

block 14 (primary current reader) and produces a

square wave with variable duty cycle limiting the

primarycurrenttoamaximum pre-set value under all

circumstances.

Block 16

Adder

Consistingof: U1D (controlboard)

Gathers all the information from block 14 (primary

current reader), from block 17 (alarms) and from

block 18 (potentiometer), and produces a signal with

a suitable voltage for processing by block 15 (duty

cyclemaker).

Block 17

AlarmBlock

Consistingof: U1A, U1C (controlboard)

When an alarm is detected the machine output

current is drastically reduced by directly adjusting

and changing the reference signal obtained from

block18(potentiometer).

Block 18

Potentiometer

Consistingof: R7

Thisisusedtocreatethereferencevoltageneededto

adjust the output current: when the potentiometer is

turned the cursor voltage varies, thus varying the

currentfromtheminimumtothemaximumvalue.

Block 19

YellowLEDalarmlight

Consistingof: D26 (yellow)

Itisswitchedonbyblock17(alarms)intheeventof:

1) Triggering of thermostatic capsule on power

transformer.

2) Triggeringduetoundervoltage.

3) Triggeringduetoovervoltage.

4) Short circuit at output (electrode holder and earth

cable connected to each other or electrode stuck

topiecebeingwelded).

Block 20

Maximumcurrentadjustment

Consistingof: R32, R33, R42

Used to adjust the maximum welding current

suppliedbythepowersource.

Block 21

Powertransformerthermostat

Consistingof: ST1 thermostatic capsule.

When the temperature of the power transformer is

too high, this safeguard is triggered. It is reset

automaticallyafterthealarmconditionhasceased.

Block 22

Galvanicseparator

Consistingof: ISO1

The signal from the thermostatic capsules is

separated galvanically and sent to block 17 (alarms)

foridentificationofpossiblealarmcondition.

Block 23

Overvoltagesafeguard

Consistingof: R3, R4 andpartofthecontrolsection

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

thisrangethesafeguardtriggers).

Block 24

Undervoltagesafeguard

Consistingof: R5, R6 andpartofcontrolboard

If the main supply voltage falls below the minimum

allowed value this safeguard triggers (a tolerance of

approx.±15% of thepower supply voltageis allowed:

outsidethisrangethesafeguardtriggers).

Block 25

PowersupplyLED

Consistingof: D2

Shows that the machine is correctly powered and

readytoweld.

On machines operating exclusively at 230V it is

green.

Block 26

Fan

Cools the power components. On machines

operatingexclusivelyat230Vitispowereddirectlyby

block12 (at 12V).

ILLUSTRATIONS

TECNICA 1400 - 1600

- 5 -

EMC FILTER

RECTIFIER BRIDGE

PRE-CHARGE

FLY-BACK

TRANSFORMER

POWER TRANSFORMER

POTENTIOMETER

POWER

SUPPLY LED

ALARM LED

15 DUTY CYCLE

MAKER

GALVANIC

SEPARATOR

INDUCTANCE

THERMOSTATIC

CAPSULE

ON POWER

TRANSFORMER

SECONDARY

EMC FILTER

SECONDARY

DIODES

FILTER

CHOPPER

DRIVER

Power board

TECNICA 1400 - 1600

General wiring diagram – TECNICA 1400 – 1600

- 6 -

WIRING DIAGRAM

TECNICA 1400 - 1600

Wiring diagram for power – power supply/control board

- 7 -

TECNICA 1400 - 1600

Wiring diagram for power – power/driver board

IGBT

- 8 -

TECNICA 1400 - 1600

- 9 -

Wiring diagram for control board

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

TECNICA 1400 - 1600

ESSENTIAL INSTRUMENTS

1 Dual trace oscilloscope cod. 802401 (*)

2 Static load generator cod. 802110 (*)

3 Variac 0 - 300v 1500 VA cod. 802402 (*)

4 Digital multimeter

USEFUL INSTRUMENTS

5 Unsoldering station

MISCELLANEOUS

6 Cutting nippers

7 Flat jaw pincers

4 2 51 3

6 7

- 10 -

REPAIR GUIDEREPAIR GUIDE

EQUIPMENT REQUIRED

Este manual sirve para los siguientes modelos

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