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
24
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
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 -
1
EMC FILTER
3
RECTIFIER BRIDGE
4
PRE-CHARGE
12
FLY-BACK
TRANSFORMER
8
POWER TRANSFORMER
18
POTENTIOMETER
25
POWER
SUPPLY LED
19
ALARM LED
15 DUTY CYCLE
MAKER
22
GALVANIC
SEPARATOR
10
INDUCTANCE
21
THERMOSTATIC
CAPSULE
ON POWER
TRANSFORMER
11
SECONDARY
EMC FILTER
9
SECONDARY
DIODES
5
FILTER
6
CHOPPER
13
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
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
REPAIR GUIDEREPAIR GUIDE
EQUIPMENT REQUIRED
Este manual sirve para los siguientes modelos
1
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