Cod.

988672

TECHNOLO GY 175-210-188
TECNICA 140.1 - CE/GE
142
inver ter

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.......................................................11
Equipment required 11
General repair instructions 12
Troubleshooting and remedies 12
Testing the machine 15
Illustrations 18

SPARE PARTS LIST...............................................19

REPAIR SHEET......................................................23

“reparation no problem !”
 INPUT EMC FILTER RECTIFIER BRIDGE PRE-CHARGE FILTER CHOPPER CURRENT POWER SECONDARY INDUCTANCE AND SECONDARY OUTPUT
TRANSFORMER TRANSFORMER DIODES SHUNT EMC FILTER

+
-

1 2 3 4 5 6 7 8 9 10

BLOCK DIAGRAM
POWER SUPPLY AUXILIARY SEPARATOR DRIVER IGBT TERTIARY SUPPLY FAN
LED SUPPLY TRANSFORMER

28 11 13 14 12 29

TRANSFORMER DUTY CYCLE PRIMARY SHUNT AMPLIFIER MAXIMUM

PILOT MAKER CURRENT
CURRENT READER
ADJUSTMENT

-2-
AND LIMITER

+
|
15 16 18 24 23

UNDERVOLTAGE ALARM BLOCK ADDER CURRENT

SAFEGUARD POTENTIOMETER
V

27 19 17 21

CONTROL

SECONDARY DIODE POWER ALARM LED WELDING

THERMOSTAT PROCEDURE
TRANSFORMER
FUNCTION
THERMOSTAT SELECTOR

MMA
TECHNOLOGY 175-210-188CE/GE

TIG
-LIFT
OPERATION AND WIRING DIAGRAMS

26 25 20 22
 TECHNOLOGY 175-210-188CE/GE
ANALYSIS OF THE BLOCK DIAGRAM Block 9
Inductance and shunt
NOTE: Unless indicated otherwise, it should be assumed that Consisting of: L1, R38.
the components are assembled on the power board. The inductance levels the secondary board diodes' output
current making it practically continuous/direct. The shunt
reads the current circulating in the inductance and sends it to
block 24 (shunt amplifier), which will process the data.
Block 1
EMC Filter
Consisting of: C24, C25, C26, L2.
Block 10
Prevents noise from the machine from being transmitted along Secondary EMC Filter
the main power line and vice versa. Consisting of: C21, C22.
Prevents noise from the power source from being transmitted
through the welding cables and vice versa.
Block 2
Rectifier bridge
Consisting of: D31, D32.
Block 11
Converts the mains alternating voltage into continuous pulsed Auxiliary supply
Constisting of: T2, D1, Q2, U5
voltage.
Takes and stabilizes the voltage coming from block 2 (rectifier
bridge) and makes it suitable to supply correctly: block x
Block 3 (supply led) block x (transformer separator) and block 3 (pre-
Pre-charge charge).
Consisting of: K1, K2, R40.
Prevents the formation of high transitory currents that could Block 12
damage the main power switch, the rectifier bridge and the Tertiary supply
electrolytic capacitors. Constisting of: D11, D57, Q0,D8
When the power source is switched on the relay K1 and K2 are Takes and stabilizes the voltage coming from tertiary wiring
de-energised, capacitors C27, C29, C30, C31 are then block 7 (power transformer) and makes it suitable to supply
charged by R40 When the capacitors are charged the relay is correctly block x (fans) and block 3 (pre-charge).
energised.
Block 13
Block 4 Separator transformer
Filter
Consisting of: C27, C29, C30, C31. Consisting of: T3.
Converts the pulsed voltage from the rectifier bridge into Supplies two signals, which are separated galvanically from
continuous voltage. one another, that will be sent to power block 14 (driver).
Block 5
Chopper Block 14
Consisting of: Q6, Q7, Q8, Q9. Driver
Converts the continuous voltage from the filter into a high Consisting of: Q5, D19, D20, Q10, D25, D26.
frequency square wave capable of piloting the power Takes the signal from block 13 (flyback power supply) and,
transformer. controlled by block 15 (duty cycle maker), makes the signal
Regulates the power according to the required welding suitable for piloting block 5 (chopper).
current/voltage.
Block 15
Block 6 Transformer Pilot
Current transformer Consisting of: Q4, D14, D15, D16.
Consisting of: T1.
The C.T. is used to measure the current circulating in the power Amplifies the signal arriving from block 16 (duty cycle
transformer primary and transmit the information to block 17 maker), needed to pilot block 13 (separator transformer).
(primary current reader and limiter).
Block 16
Block 7 Duty cycle maker
Power transformer Consisting of: U2 (control board).
Consisting of: T4. Processes the information from block 17 (adder) and block 18
Adjusts the voltage and current to values required for the (primary current reader and limiter) and produces a square
welding procedure. Also forms galvanic separation of the wave with variable duty cycle limiting the primary current to a
primary from the secondary (welding circuit from the power maximum pre-set value under all circumstances.
supply line).
Block 17
Block 8 Adder
Secondary diodes Consisting of: U1C (control board).
Consisting of: D46, D47, D48, D49, D51. Gathers all the information from block 18 (primary current
D46, D47, D48 converts the current circulating in the reader and limiter), from block 19 (alarms) and from block 21
transformer to a single direction, preventing saturation of the (current potentiometer), and produces a signal with a suitable
nucleus. voltage for processing by block 16 (duty cycle maker).
D49, D51 recirculate the inductance output current (block 9)
when the IGBT's are not conducting, bypassing the power
transformer (block 7).

-3-
 TECHNOLOGY 175-210-188CE/GE
Block 18 Block 27
Primary current reader and limiter Undervoltage safeguard
Consisting of: R79, R80, R81, R82, R83, R84 (control board). Consisting of: R7, R9 and part of control board.
Reads the signal from block 6 (current transformer) and scales If the main supply voltage falls below the minimum allowed
it down so it can be processed and compared in block 16. value this safeguard triggers (a tolerance of approx. ±15% of
the power supply voltage is allowed: outside this range the
Block 19 safeguard triggers).
Alarm Block
Consisting of: U1A (control board). Block 28
When an alarm is detected the power source output current is Power supply LED
drastically reduced by making direct adjustments to block 16 Consisting of: D43.
(duty cycle maker) and directly changing the reference signal Indicates when the power source is correctly powered and
obtained from block 21 (current potentiometer). ready for use.

Block 20 Block 29
Alarm LED Fan
Consisting of: D39. Consisting of: V1, V2.
It is switched on by block 19 (alarms) in the event of: Powered directly by block 12 (Tertiary supply) and cools the
1) Triggering of thermostatic capsule/thermostat on power power components.
transformer.
2) Triggering of thermostatic capsule on secondary
diodes.
3) Triggering due to undervoltage.
4) Short circuit at output (electrode holder clamp and earth
cable connected to one another or electrode stuck to piece
being welded).

Block 21
Current potentiometer
Consisting of: R49.
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 22
Welding procedure function selector
Consisting of: SW1
The switch is used to select the type of welding process:
MMA, TIG-LIFT.

Block 23
Maximum current adjustment
Consisting of: R48, R55.
Used to adjust the maximum cutting current to be supplied by
the power source.

Block 24
Shunt Amplifier
Consisting of: U3A (control board)
Amplifies the signal from block 9 (inductance shunt) and
makes it appropriate for block 17 ( Adder).

Block 25
Power transformer thermostat
Consisting of: ST2.
When the temperature of the power transformer is too high,
the thermostat transmit the information to block 19 (Alarm
Block). It is reset automatically after the alarm condition has
ceased.

Block 26
Secondary diode thermostat
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 19 (Alarm Block). It is reset
automatically when this alarm condition is no longer present.
-4-
 TECHNOLOGY 175-210-188CE/GE
ILLUSTRATIONS

Power board
(22)
(28) WELDING
(21) POWER (20) PROCEDURE (10)
CURRENT SUPPLY ALARM FUNCTION SECONDARY
POTENTIOMETER LED LED SELECTOR FILTER EMC

(9)
CONTROL INDUCTANCE
BOARD AND SHUNT

(8)
SECONDARY
DIODES (7)
POWER
TRANSFORMER

(11)
AUXILIARY
POWER
SUPPLY

(6)
CURRENT
TRANSFORMER

(15)
TRANSFORMER
(2) PILOT
PRE-CHARGE

(13)
(3) SEPARATOR
RECTIFIER TRANSFORMER
BRIDGE

(5)
(1) CHOPPER
PRIMARY EMC
FILTRE

(4)
FILTER

-5-
 WIRING DIAGRAMS

J7 J3
POW E R PCB CON T RO L PCB
1 +5V 1
2 +17V8 2
3 D R+ 3
PE CN11 4 GND 4
5 T A+ 5
6 TA - 6
L1 7 SH - 7
L1 CN4 8 S H+ 8
1 2 VO L T -
9 9
Indu ttance 10 VO L T+ 10
11 PO T _ IN 11
N (L2 ) CN9 12 T AR+ 12
4 5 T AR -
13 13
14 VCH ECK 14
S1 ON LY FOR 15 FAU L T 15
ON /O F F GE VER S O
I N 16 16
17 17
18 18
19 19
20 SW 20
21 LED 21
V1+ 22 GND 22

-6-
V1-

J21
V1 O U T+
F an
V 2+
R 38
SH - S hun t J22
OU T -
V2-
Wiring general diagram - TECHNOLOGY 175 - 210 -188 CE/GE

V2
F an
TECHNOLOGY 175-210-188CE/GE
 MOD E L G
I B T Q6 ,Q7 , C28 C29 ,C30 ,C31 D31 , D32 K1 , K 2 JP 1 JP 2 R 55
Q8 ,Q9
D31 =G B PC3508 /10 K1 = 15Vdc 45mA /250V 16A
T ECHNO LOG Y 175 SGW 30N60 NM
. . 470u 400V A ll D32 =G B PC3508 /10 K2 = 15Vdc 45mA /250V 16A O FF ON 27K 0W 25 5%
D31 =G B PC3508 /10 K1 = 15Vdc 45mA /250V 16A
T ECHNO LOG Y 210 SGW 30N60 NM
. . 680u 400V A ll D32 =G B PC3508 /10 K2 = 15Vdc 45mA /250V 16A O FF ON 10K 0W 25 5%
D31 = 36M B 100A K1 = 15Vdc 45mA /250V 16A
T ECHNO LOG Y 188G E /C E SGW 30N60 470u 450V A ll 470u 450V A ll D32 = N M
. . K2 = 15Vdc 45mA /250V 16A ON O FF 33K 0W 25 5%

R 40
47R 8W 5% T P 39
JP 2 R 42 D34 R 44 D33
V .T . 1R 0W 25 5% Q6 NM
. . 20R 13W 5% R U R P 860
T P1 T P2 T P3 V .T .
D31 JP 1 K2 T P 40
L2 V .T . V .T . V .T . R 43
CN4 295uH 1R 0W 25 5% Q7
V .T . C33
10n 630V K P
Fas ton-M 6 ,3x0 ,8

H2
C24 R 39
1u 275V M K P 1M 0W 5 5% H1 D is s p
i atore
K1 H3 D37
CN9 D is s p
i atore V .T . M U R 1560
D is s p
i atore
Fas ton-M 6 ,3x0 ,8
T P 37
R 46
1R 0W 25 5% Q8 D36 R 45 D35
T P4 T P5 T P6 V .T . NM
. . 20R 13W 5% R U R P 860
CN11
Wiring diagram power board - primary

T P 38
R 47
Fas ton-M 6 ,3x0 ,8 C28 R 14 C29 C30 C31 C27 1R 0W 25 5% Q9 D38
C25 C26 D32 NM
. . 3K 3 5W 10% V .T . V .T . V .T . 220n 630V M K P V .T . M U R 1560
4n7 250V K P 4n7 250V K P V .T . C34
CN8 10n 630V K P

NM
. .
T P8 T P 11 +5V T P 21 P ower board T echno o
l gy_B Power board T echno o
l gy_C

-7-
R E LE _K2_A
CO R R M
I AX R E LE _K2_B T R A FO _PN
R E LE _K1_A T R A FO _P P
EM E T _ L
GA T E _ L
E M E T _H
G A T E _H
R 49 R 48 R E LE _K1_B
10K L IN 0W 2 10% 47K 20 T 0W 5 10% AC+ SP - SP -
+5V +17V 8 AC -
S P+ S P+
I O

T P 22 DR+
R 55 R 56 R 57 VCH ECK R E LP R E LP
B V .T . NM. . NM. .
T A+
TA -
T E RM C

SH -
S H+
VO L T -
VO L T +

1
2
3 D R+
4 F15246B F15246C
5 T A+
6 TA -
7 SH -
8 S H+
9 VO L T -
10 VO L T+
11 PO T IN
J7 12 T A R+
13 TAR -
14 VC H E C K T P7 SW 1 +17V8 T P 9
15 FAU L T 1B 11

F o r i 22 pa s so 2 .5
16 C A DM
17 C AD A TG
I
18 C AD 1
19 C AD 2
TECHNOLOGY 175-210-188CE/GE

20 SW
21 LED
22 +17V8 MMA
T P 18 T P 19 T P 20 T P 16 T P 17
B
B T P 10
1
2 +5V
3 R 50
4 2K 2 0W 25 5%
5 R 12
6 NM. . C 35
J8 7 1u 63V M K T B T P 23 T P 24
8 D39 C44
9 Ga
i llo 5mm 100u 25V A ll
10 R 13

F o r i_ 12 pa s so 2 .5
11 NM. .
12
D 40 D41
1N 4148 1N4148
 20V +17V8
C14
NM
. .
T P 27 +5V
D2 D4 +17V8
1N4004 1N4148
T P 26
T P 25
Q2 R 58 U5 LM 78L05
22R 0W 5 5%
T IP 50 1 3
IN OU T R E LE _K1_A

H4

GND
C6 D56 R 59 D54
D1 C40 10u 25V A ll NM
. . 10K 0W 25 5% 1N4148

2
W 02G 33u 25V A ll
T2 R 51 R1 D55 R E LE _K1_B

1
230 /18 4VA 3K 3 0W 5 5% 470R 2W 5%
2 Q1
AC+ D7 B M P S A13
VCH ECK 10V 0W 4 5%

3
AC - D43 10V 0W 4 5%
Verde 5mm 2 1
C1 D3 C2 C3 R9 no so d
l er no so d
l er
470u 50V A ll 18V 1W 5% 10u 25V A ll 470u 25V A ll 12K 0W 25 5% C42
33u 25V A ll

B B

C36 T P 29
1n 100V X7R

T P 28
D10 C37 H4
D11 B Y V27-200 1n 100V X7R Q0
B Y V27-200
T IP 122
S P+ R E LP
D57 V1 V2
B Y V27-200 R8 12Vdc 12Vdc
3K 3 0W 5 5% +V1 +V2

-V1 -V2 R E LE _K2_A

C11 C10 C9 C38 C39 D8 C43 D6 C8
100u 63V A ll 1u 63V M K T 1u 63V M K T 1u 63V M K T 1u 63V M K T 15V 0W 4 2% 47u 25V A ll 1N4148 100N 63V M K T
Wiring diagram power board - power / driver

SP - R E LE _K2_B

-8-
B

GA T E _H
D 19 D 20 D 52
B Y V 27 -200 B Y V 27 -200 NM. .
R 31 D21
R 28 18V 0W 4 5%
T P 30
10R 0w25 5%
120R 0W 25 5%
+17V 8

2
C 19
D 18 1 NM. .
B Y V 27 -200 Q5
BC 327 D22

3
D 14 18V 0W 4 5%
10V 0W 4 5%
T3
T I 117303 T P 32
4
D 15
10V 0W 4 5% C 16 R 29 R 30
8 1u 63V M K T 470R 0W 25 5% 1K 0W 25 5%
3 EM E T _H
D 16 5 GA T E _L
B Y V 27 -200 1
D 25 D 26 D 53
C 41 C 15 B Y V 27 -200 B Y V 27 -200 NM. .
33u 25V A ll 1u 63V M K T 6
T P 34 R 27
R 33 T P 31
10R 0W 25 5%
R 25 120R 0W 25 5% D23
220R 0W 25 5% 18V 0W 4 5%
Q4
2

D R+ IR FD 110 C 18
D 17 1 NM. .
B Y V 27 -200 Q 10
BC 327 D24
3

R 26 18V 0W 4 5%
1K 0W 25 5% T P 33

B C 17 R 34 R 32
TECHNOLOGY 175-210-188CE/GE

1u 63V M K T 470R 0W 25 5% 1K 0W 25 5%
EM E T _L
 R E LP

T P 35 T P 36
J2 R 35
IN /OU T 1K5 0W 25 5%

J1
IN /OU T R 11 T E RM C
I O
10K 0W 25 5%
Q3
BC337
MOD E L D46 , D48 D47
C20 R 60
D46 = S T T H 6003CW 100n 63V M K T 1K 0W 25 5%
T ECHNO LOG Y 175 D48 = S T T H 6003CW D47 = N M
. .
D46 = S T T H 6003CW B
T ECHNO LOG Y 210 D48 = S T T H 6003CW D47 = N M
. . B

D46 = N M
. .
T ECNO LOG Y 188CE /G E D48 = N M
. . D47 = S T T H 6003CW

D44

1
NM
. .

3
D46
Wiring diagram power board - secondary

V .T . VO L T -

2
S T1 VO L T+
H4 80°C

1
J21

-9-
3 OU T+
D47 Foro
V .T .

2
D29 D30
S T2 NM
. . NM
. . R 37 C21
110 C
° 100K 0W 25 5% 10n 300V M K P

1
D 48

3
3
3

V .T .
1 2 1 2 1 2 JP 4
3 TO1
R 41 D49 D50 D51 T erm inale_OU T
T4 10R 5W 5% S T T H 6003CW NM
. . S T T H 6003CW so d
l er
T ras fo_1 /2 D 27
NM. . H5

2
T R A FO _P P C 32 C22
1n5 630V K P L1 10n 300V M K P
11uH R 38
180A = 210mV J22
OU T -
Foro
F ILO T A
T R A FO _P N
J9 T1 J10 S H+
1 /200 25A SH -
2 3 T P 15 T P 14
B
J5

1
4
S P+
TECHNOLOGY 175-210-188CE/GE

A B SP -
J6

T P 12 T P 13

TA -

T A+
 TECHNOLOGY 175-210-188CE/GE
Wiring diagram power board
+5V +5V

C20 5 EN1
R 57 U 7A 100n 50V X7R R 33 17V8
R 55 10K 0805 5% 14 40106 3 4
1K 0805 5%
1 2 4K 7 0805 1% U 4B
CD4066BC
7 T P8 T P9 R 34 C13 +5V C10
+5V

2
3 T es t_Po in t T es t_Po in t 470K 0805 1% 100n 50V X7R 100n 50V X7R

3
C22
220n 50V X7R 1 2 1 2 T P4
3 11 10 9 8 R 27 T es t_P o in t

4
D28 D22 1K 0805 5%
B A S 40-04 D36 U 7E U 7D BA S 40-04 5 0 ..10 V
B AV70 40106 40106 7 SET
R 29 C16 +5V 6

1
10K 0805 5%
+5V 17V8 U 3B
J3

11
100n 50V X7R LM 324D
14
1 13 EN1
2 R 30
3 D R+
2 1 R 16 R 59
4 7 4K7 0805 1% 4K7 0805 5%
5 T A+
6 TA - 1K 0805 5% U 4A R 17
7 SH - C12 CD4066BC 4K7 0805 1%
8 S H+ 100n 50V X7R
9 17V8
10 VO L T+
PO T -IN
11
12 T AR+
13 VCH ECK T AR -
14 Q7 R 53
15 FAU L T BC807 39K 0805 1%
CADM
16 CAD A
17 CAD 1 T P1
18 CAD 2 T es t_P o in t
19 T P5
SW R 10
20 T es t_P o in t

4
LED 13K 0805 1%
21 3
22 1 A L LARM
+5V 2
70354-301 U 1A
R 23 C7 MC33074D

11
2K0 0805 1% 10n 50V X7R T P2
T es t_P o in t

2
R 87
11

SW
3K0 0805 1% D38
13 BA S 40-06
14 3
12
U 1D R 88 C40
4

MC 33074D 2K0 0805 1% 100n 50V X7R

1
CO R TO

S T AR T

T P6 T P7
2

T es t_P o in t T es t_P o in t R 31
+5V 4K7 0805 1%

2
3 5 6 13 12 6 EN1 R 37 T P3

4
R 38 1K 0805 5% T es t_P o in t

4
D 37 U 7C U 7F VR E F 9 8 12
R 56 U 7B B A V 70 40106 40106 14 D25 3 10
R 58 10K 0805 5% 40106 R 49 4K7 0805 1% U 4C 13 BA S 40-05 8 OVE R S E T
1

1K 0805 5% 100K 0805 5% CD4066BC U 3D 9

3 4 LM 324D U 3C

11
LM 324D 0 ..2 ,5 V

11
+5V 12 EN1 R 32
3

C 23 R 36 3K3 0805 1%
220n 50V X 7R 1 2 10 11
D 29 4K 7 0805 1% U 4D
B A S 40 -04 CD4066BC CC R 39 R 60
R 35 C15 +5V 4K7 0805 1% 4K7 0805 5%
470K 0805 1% 100n 50V X7R
3

1 2
D23
R 51 BA S 40-04
Q5
BC817
4K 7 0805 1%
C21 R 50
100n 50V X7R 4K7 0805 1%

VR E F
2

Q1
17V8 BC817
T A+ 3 T P 13 R 19
D11 R 83 R 18 VR E F
B AV99 680R 0805 1% T es t_Po in t 820R 0805 1%
C11 7K5 0805 1%
100n 50V X7R
7
11

R 24 R 81 R 79 R 80 R 82
1K 0805 5% 39R 1206 1% 39R 1206 1% 39R 1206 1% 39R 1206 1% R 15 2 4
V FB R T /C T
VCC

0R 0805 3 8
2 IS EN VR E F
1
D12 R 84 C14 5 COM P 6
GND OU T
3

24V 0W 4 5% 200R 0805 1% 100p 50V X7R R 21

TA - NM.
U2 C8 C9 C42
UC3845AD1 10n 50V X7R 100n 50V X7R 2n2 50V COG
R 45 17V8
1K 0805 5%
R 46
4K 7 0805 5% R 42
R ID D U T Q4 10K 0805 5%
BC807 R5
11

D R+
10K 0805 5% D42 R 62
6 1K 0805 5%
7 C26
5 560p 50V COG R 61
6K8 0805 5%
R 12 R 64 U 1B L L4148 17V8
4

3K 3 0805 5% 100K 0805 5% MC33074D 17V8

R 63
27K 0805 5% S T AR T
17V8 T P 14
3

T es t_P o in t R 48 R 47
12

VR E F 9 1K 0805 5% 47K 0805 5%

6 14 Q3
1 8 MM B F170
7
R6 U 5C
12

3K 3 0805 5% R 65 U 5B LM 339 C19

3

9K 1 0805 1% LM 339 22u 25V A ll

D4
G L41G R 14
1K 0805 5% R ID DU T
VO L T+ 17V8
R9
100K 0805 1% 17V8 C17 T P 16
C6 100n 50V X7R
10n 50V X7R D26 T es t_P o in t
R 13 C4 VR E F R 44 L L4148
8K 2 0805 1% 10n 50V X 7R 2K7 0805 5% U 5D
12

T P 15
R 40 U 5A LM 339
T es t_P o in t VR E F 10
3

SH - 13K 0805 1% LM 339 R 43

5 33K 0805 5% 13
R 25 2 11
4
R 28
3

4K 7 0805 5% 2K 2 0805 1%
12

SW Q6 CO R TO C18
BC 817 22u 25V A ll
R 41 CC
3K 3 0805 1%
C 24 R 26
100n 50V X 7R 10K 0805 5% Q2
MM B F170
D2
5V 6 0W 4 5% D3
L L 4148
R 52 +5V 1 3
82K 0805 5%
T A R+ C2
2

1n 50V X7R
T AR -

R 86 R7 C3
T P 10 NM. . 1K 0805 5% 10n 50V X7R
R1 T es t_P o in t
4

1K 0805 5% R3
S H+ 3 22K 0805 5%
1 T P 12
2 T es t_Po in t BAV99
11

U 3A D39 D40
LM 324D 9 L L4148
11

8 1 2
R 54 C1 R8 R2 10
47R 0805 5% 1n 50V X 7R 4K 7 0805 1% C 41 4K 7 0805 5% U 1C
3

100p 50V X 7R MC33074D

4

SH - C5 R 11
NM
. 1K 0805 5%

+5V C25
17V 8 100n 50V X7R
T P 11
D 43
R 20 R4 T es t_P o in t B A S 40 -04
4K 7 0805 1% 47K 0805 1%
SET 1 2 A L LARM
3

R 22 FAU L T
OVE R S E T 4K 7 0805 1%

- 10 -
 TECHNOLOGY 175-210-188CE/GE

REPAIR GUIDE
EQUIPMENT REQUIRED

4 1 3 2 5

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
6 Miscellaneous tools

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

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 TECHNOLOGY 175-210-188CE/GE
WARNING:
BEFORE PROCEEDING WITH REPAIRS TO
THE MACHINE READ THE INSTRUCTION
MANUAL CAREFULLY.
WARNING:
EXTRAORDINARY MAINTENANCE SHOULD
BE CARRIED OUT ONLY AND EXCLUSIVELY
BY EXPERT OR SKILLED ELECTRICAL-
MECHANICAL PERSONNEL.
WARNING:
ANY CHECKS CARRIED OUT INSIDE THE
MACHINE WHEN IT IS POWERED MAY CAUSE
SERIOUS ELECTRIC SHOCK DUE TO DIRECT
CONTACT WITH LIVE PARTS.
GENERAL REPAIR INSTRUCTIONS
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 300°C 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.
- 12 -
TROUBLESHOOTING AND REMEDIES
1.0 Disassembling the machine
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.
- remove the current adjustment knob on the front panel of the
machine (fig. 1);
- undo the 4 screws attaching the handle to the top cover (fig. 1).
- undo the 8 screws fastening the back and front plastic panels; 4
for the cap (fig. 1).
- undo the 2 screws attaching the top cover to the base: 1 screw
on each side (fig. 1).
- undo the 2 screws fastening the top cover to the metal structure.
- slide out the top cover upwards
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.
2.0 Cleaning the inside of the machine
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 Q6, Q7, Q8, Q9;
- rheofores of recirculating diodes D37, D38;
- rheofores of secondary power diodes D46, D47, D48, D49, D51;
- thermostat ST2 on power transformer;
- thermostat ST1 on secondary diode dissipator;
- control board.
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 R49 (fig. 3)
Probable cause:
- mechanical shock.
Relay K1, K2 (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.
Electrolytic capacitors C27,C29, C30, C31 (fig. 3)
Probable cause:
- mechanical shock;
- machine connected to power supply voltage much higher
than the rated value;
 TECHNOLOGY 175-210-188CE/GE
- 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 Q6, Q7, Q8, Q9 (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 D37, D38 (fig. 4)
Probable cause:
- excessive overheating related to faulty operation.
Secondary diodes D46, D47, D48, D49, D51 (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)
Inspect the windings for colour changes. Probable causes:
- power source connected to a higher voltage than 280Vac;
- ageing after a substantial number of working hours;
- excessive overheating related to faulty operation.
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.
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 D31, D32 (fig. 3);
- IGBT's Q6, Q7, Q8, Q9 (absence of short circuits between
collector-gate and between emitter-collector fig. 4);
- secondary board diodes D46, D47, D48, D49, D51
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;
- MOSFET Q4 (absence of short circuits between drain-gate
and drain-source (fig. 4).
B) With the multimeter set in ohm mode check the following
components:
- resistor R1: 47ohm (pre-charge fig. 3);
- resistor R14: 3.3ohm (unloads fig. 3);
- resistors R44, R45: 22ohm (primar y snubber fig. 3);
- resistor R41: 10ohm (secondary snubber fig. 3);
- thermostat continuity test on the power transformer: clean
the resin from the bump contacts of ST2 (J2) and measure
the resistance between the two bump contacts, it should be
approx. 0 ohm (fig. 2B).
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
- 13 -
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 U5 (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 R49 on maximum (turn
clockwise as far as it will go).
D) Position the switch SW1 in MMA.
E) Connect the power supply cable to a single-phase variac
with variable output 0-300 Vac.
6.2 Tests for the TECHNOLOGY 175 -210-188CE/GE
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 D43 lights up (fig. 3),
- the fan for the power transformer starts up correctly,
- the pre-charge relay K1 commutes (fig. 3),
- the unloads relay K2 commutes (fig. 3),
- for voltages close to the rated power supply value (230Vac
±15%) the power source is not in alarm status (yellow LED
D39 off).
NB. 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.
FIGURA A
SETTINGS:
- PROBE x10;
- 5V/Div;
- 5µsec/Div.
VERIFY THAT:
- FREQUENCY IS
52KHz ±10%;
- AMPLITUD IS 22V
±10%.
N.B. if no signal is present, it may be necessary to replace the
MOSFET Q4 (fig. 3).
C) With the multimeter set in volt mode make sure that
(fig. 3):
- voltage between the negative of diode bridge D31 (-) and the
catode D11 (-) is equal to +40V ±10%;
- voltage between the negative of diode bridge D31 (-) and the
pin 3 of Q2 (+) is equal to +17.8V ±5%;
- voltage between the negative of diode bridge D31 (-) and the
pin 3 of U5 (+) is equal to +5V ±5%;
- voltage between the pads V1- and V1+ is equal to +14V ±5% ;
- voltage between the pads V2- and V2+ is equal to +14V ±5%;
D) Set up the dual trace oscilloscope. Connect the probe
CH1(x100) to the Q8 collector and probe CH2 (x10) to the
 TECHNOLOGY 175-210-188CE/GE
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.
FIGURA B
SETTINGS:
- PROBE CH1 x100;
- 100 V/Div;
- PROBE CH2 x10;
- 10V/Div;
- 5µsec/Div.
TIME TOLLERANCES
±20%.
VERIFY THAT:
- AMPLITUDE ON CH1
IS 320V ±10%;
- POSITIVE
AMPLITUDE ON CH2
IS +19V ±10%;
- NEGATIVE
AMPLITUDE ON CH2
IS -2V ±10%.
F) Repeat this test also for Q6, Q7, Q9 (for Q6 and Q7 use the
differential probe).
N.B. if the signal is not present there could be a fault in the
IGBT driver circuit (fig. 3) or in the control board (fig. 2A, in this
case we recommend replacing the board).
G) Set the two-channel oscilloscope ready. Connect the probe
CH1 (x100) on the collector of Q8 and the mass on the sender
of the same Q8 probe CH2 (x10) on the pin 9 of strip J11. The
masses are to be connected together on the sender of Q1.
Connect the probe CH2 on the pin 5 of J7 and the mass on pin
6 of the same J7. N.B. In case you wish to measure the two
wave shapes together as indicated in the figure it is necessary
to use the differential probe (1/20).
H) Make sure the waveform displayed on the oscilloscope
resembles fig. C and that the output voltage over OUT+ and
OUT - is equal to +100Vdc±10%.
FIGURA C SETTINGS:
- PROBE CH1 x100
- 100V/Div;
- P R O B E C H 2
DIFFERENTIAL
PROBE (1/20);
- 100mV/Div;
- 5µsec/Div.
TIME TOLLERANCES
±20%.
VERIFY THAT:
- AMPLITUDE ON CH1
IS 320V ±10%;
- P O S I T I V E
AMPLITUDE ON CH2
50mV ±10%.
- N E G A T I V E
AMPLITUDE ON CH2
-150mV ±10%
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 D39 is off, fig. 3). N.B. If the
machine remains in alarm status (and this is not due to a fault in
the control board) there could be a fault R9 or D7 (fig. 3).
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).
- 14 -
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.
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);
- undo the 3 screws fastening the board to the bottom (fig.
2B);
- remove the board from the metal structure, lifting it
upwards.
N.B. for assembly proceed in the reverse order and remember
to insert the toothed washer on the earth screw.
A) Please read the procedure for replacing the IGBT's
carefully: (fig. 4).
The 4 IGBT's are attached to 2 different dissipators and
whenever a replacement is required, both IGBT's should be all
replaced.
- undo the screws attaching the dissipator to the board to
replace Q6, Q7 (fig. 2B);
- undo the screws attaching the dissipator to the board to
replace Q8, Q9 (fig. 2B);
- remove the 4 IGBT's and the 2 diodes D37, D38 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 4 IGBT's.
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 R42, R43, R46 and R47 could have
burst and/or diodes D21, D22, D23 and D24 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 D37 and D38 (WARNING! Make sure there is
insulation between the case of diode D38 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%);
 TECHNOLOGY 175-210-188CE/GE
- solder the terminals taking care not to let the solder run (1/20), on the pin 5 of J7 (control card) and the mass on pin 6 of
along them; the same strip J7.
- on the welding side cut away the protruding part of the C) Set up the multimeter in DC mode and connect the prods to
rheofores and check they are not shorted (between the the OUT+ and OUT- bump contacts.
gate and emitter in particular). D) Connect the power supply cable to the 230Vac power
supply.
B) Please read the procedure for replacing the secondary WARNING! During tests the operator must avoid contact with
board diodes carefully (fig. 4): the metal parts of the torch because of the presence of
The SECONDARY DIODES are attached to the same dangerous, high voltage.
dissipator, and when a replacement is required, all of them
should be replaced: 1.2 Tests for the TECHNOLOGY 175-210-188CE/GE
- undo the screws attaching the dissipator to the board, to A) Minimum load test:
replace diodes D46, D47, D48, D49 and D51; - set up the static load generator with the switch settings as in
- remove the secondary diodes unsoldering the rheofores the table in Fig. D;
and cleaning any solder from the bump contacts on the - on the front panel position the current potentiometer at
board; (approx.) half way.
- remove the dissipator from the board; - switch on the main switch;
- remove the spring locking the diodes; - activate the statico load generator and make sure that:
- clean any irregularity or dirt from the dissipator. If the diodes - the waveforms displayed on the oscilloscope resemble
have burst the dissipator may have been irreversibly those in Fig. D;
damaged: in this case it should be replaced; - the output current is +6Adc±20%, and the output voltage
- apply thermo-conductive grease following the general is +20.2Vdc±20%.
instructions; - deactivate the static load generator and switch off the main
- insert the new diodes between the dissipator and the switch.
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); FIGURA D
- place the dissipator with the new components in the PCB
bump contacts and fasten them down with the screws SETTINGS:
(torque wrench setting for screws 1 Nm ±20%); - PROBE CH1 x100
- 100V/Div;
- solder the terminals taking care not to let the solder run - PROBE CH2 differential
along them; probe (1/20)
- 100mV/Div.
- on the soldering side cut away the protruding part of the - 5 µsec/Div.
rheofores and check they are not shorted (between
TIME TOLLERANCES ±20%.
cathode and anode);
N.B. make sure resistor R41 and capacitor C32 on the snubber VERIFY THAT:
- AMPLITUDE ON CH1 IS
have been soldered to the PCB correctly (fig. 3). 320V ±10%.
- AMPLITUDE ON Ch2 IS
60mV ±10%.
C) Please read the procedure for replacing the control
board (fig. 3):
Whatever fault occurs in the control board, we strongly
recommend its replacement without attempts at repair. To
remove it, cut and then unsolder from the power board the
connector keeping it fixed perpendicular to the PCB, replace it
1 2 3 4 5 6 Switch number
and re-solder the connector. 1 0 0 0 0 0 Position number

TESTING THE MACHINE

Tests should be carried out on the assembled machine before B) Intermediate load test:
closing it with the top cover. During tests with the machine in - set up the ohmic load with the switch settings as in the table
operation never commute the selectors or activate the ohmic in fig. E;
load contactor. - on the front panel turn the current potentiometer to 60A
WARNING! Before proceeding to test the machine, we should (approx. half-way);
remind you that during these tests the power source is - start up the ohmic load and make sure that:
powered and therefore the operator is exposed to the danger - the waveforms displayed on the oscilloscope resemble
of electric shock. those in Fig. E;
The tests given below are used to verify power source - the output current is equal to +60Adc ±10% and the
operation under load. output voltage is equal to +22.4Vdc ±10%.
- switch off the ohmic 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 the two channel oscilloscope by connecting the probe
CH1 (x100) on the collector of Q8 and the mass on the sender
of the same Q8. Connect the probe CH2, of differential type
- 15 -
 TECHNOLOGY 175-210-188CE/GE
FIGURA E using trimmer R48 (fig. 3).
- switch off the ohmic load.
SETTINGS:
- PROBE CH1 x100
- 100V/Div;
- PROBE CH2 differential FIGURA G
probe (1/20);
- 100mV/Div;
- 5 µsec/Div. SETTINGS:
- PROBE CH1 x100
TIME TOLLERANCES - 100V/Div;
±20%. - PROBE CH2 differential
probe (1/20);
VERIFY THAT: - 200mV/Div;
- AMPLITUDE ON CH1 IS - 5µsec/Div.
320V ±10%.
- AMPLITUDE ON CH2 IS TIME TOLLERANCES
120mV ±10%. ±20%.

VERIFY THAT:
- AMPLITUDE ON CH1 IS
320V ±10%;
- AMPLITUDE ON CH2 IS
200mV ±10%.

1 2 3 4 5 6 Switch number
2 2 2 1 1 1 Position number

C) Rated load test for TECHNOLOGY 175:

- set up the ohmic load with the switch settings as in the table 1 2 3 4 5 6 Switch number
in fig. F; 3 3 3 3 3 2 Position number
- on the front panel turn the current potentiometer to
maximum (turn clockwise as far as it will go); E) Rated load test for TECHNOLOGY 188CE/GE:
- start up the ohmic load and make sure that: - set up the ohmic load with the switch settings as in the table
- the waveforms displayed on the oscilloscope resemble in fig. H;
those in fig. F; - on the front panel turn the current potentiometer to
- the output current is equal to +160Adc ±5% and the maximum (turn clockwise as far as it will go);
output voltage is equal to +26.4Vdc ±5%; if the output - start up the ohmic load and make sure that:
current reading is not 160A ±5%, adjust the current - the waveforms displayed on the oscilloscope resemble
using trimmer R48 (fig. 3). those in fig. H;
- switch off the ohmic load. - the output current is equal to +140Adc ±5% and the
output voltage is equal to +25.6Vdc ±5%; if the output
current reading is not 140A ±5%, adjust the current
FIGURA F using trimmer R48 (fig. 3).
- switch off the ohmic load.
SETTINGS:
- PROBE CH1 x100
- 100V/Div;
- P R O B E C H 2
differential probe FIGURA H
(1/20)
- 200mV/Div;
- 5µsec/Div. SETTINGS:
- PROBE CH1 x100
TIME TOLLERANCES - 100V/Div;
±20%. - PROBE CH2 differential
probe (1/20);
VERIFY THAT: - 200mV/Div;
- AMPLITUDE ON CH1 - 5V/Div;
IS 320V ±10%; - 5µsec/Div.
- LAMPLITUDE ON
CH2 IS 180mV TIME TOLLERANCES
±10%. ±20%.

VERIFY THAT:
- AMPLITUDE ON CH1 IS
320V ±10%;
- AMPLITUDE ON CH2 IS
220mV ±10%.
1 2 3 4 5 6 Switch number
3 3 3 3 2 2 Position number

D) Rated load test for TECHNOLOGY 210:

1 2 3 4 5 6 Switch number
- set up the ohmic load with the switch settings as in the table 3 3 3 2 2 2 Position number
in fig. G;
- on the front panel turn the current potentiometer to
maximum (turn clockwise as far as it will go); F) Checking the secondary diode voltages:
- start up the ohmic load and make sure that: - set up the dual trace oscilloscope, connecting probe CH1 x
- the waveforms displayed on the oscilloscope resemble 100 to the anode of diode D46 and probe CH2x100 to the
those in fig. G; anode of diode D51. Earth connections are both made to
- the output current is equal to +180Adc ±5% and the the secondary dissipator;
output voltage is equal to +27.2Vdc ±5%; if the output - remove the multimeter from the OUT+ and OUT- bump
current reading is not 180A ±5%, adjust the current contacts;
- 16 -
 TECHNOLOGY 175-210-188CE/GE
- set up the static load generator with the switch settings as in
the table in fig. F, G or H;
- 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
waveforms displayed on the oscilloscope resemble those in
fig. I;
- deactivate the static load generator and switch off the main
switch.

FIGURA H

SETTINGS:
- PROBE CH1 x100
- 50V/Div;
- PROBE CH2 x100;
- 50V/Div;
- 5µsec/Div.

TIME TOLLERANCES
±20%.

VERIFY THAT:
- MAX REVERSE
AMPLIDUTE ON CH1
AND CH2 DOES NOT
EXCEED A 250V.

G) Running time check and closing the machine

With the load status as in fig. F, G or H 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.

H) 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.

- 17 -
 TECHNOLOGY 175-210-188CE/GE
ILLUSTRATIONS
FIG. 1
SCREWS FASTENING SCREWS FASTENING
HANDLE HANDLE
CURRENT REGULATION
POTENTIOMETER

POWER
SUPPLY LED

SCREWS
FASTENING
BACK PANEL ALARM LED
WELDING
PROCEDURE
FUNCTION
SELECTOR

DINSE SOCKET
SCREWS FASTENING
TOP COVER SCREWS
FASTENING
FRONT PANEL

FIG. 2A FIG. 2B
BUMP
NUTS NUTS
CONTACTS BUMP RHEOFORES
POWER SUPPLY FILTER CONTROL FASTENING FASTENING
THERMOSTAT CONTACTS FAN Q6, Q7
INTERRUPTOR CAPACITORS DIODES BRIDGE FAN WIRE
BOARD METALLIC ST1 (J1,J2) V1,V2
METALLIC
DISSIPATOR STRUCTURE STRUCTURE

Q6, Q7
DISSIPATOR
SCREWS
FASTENING

Q8, Q9
DISSIPATOR
SCREWS
FASTENING
FAN
SECONDARY
IGBT POWER INDUCTANCE DISSIPATOR RHEOFORES
BOTTOM DIODES
DISSIPATORS TRANSFORMER SCREWS Q8, Q9 NUTS FASTENING
SECONDARY
FASTENING METALLIC STRUCTURE
DISSIPATORS

FIG. 3 FIG. 4 PRIMARY SECONDARY DIODES

DIODE D46,D47,D48,D49,D51
D31, D32 R14 K1, K2 R40 R41 V1, V2 U5 D7,R9 Q2 R48 J7 IGBT D37
Q6, Q7

C29 R49
C31

D43

C30
D39

Sw1

C32

PRIMARY IGBT
R44 DIODE Q8, Q9
R45 Q4 St2 R38 D38

- 18 -
TECHNOLOGY 175-210-188CE/GE
ELENCO PEZZI DI RICAMBIO - LISTE PIECES DETACHEES
SPARE PARTS LIST - ERSATZTEILLISTE - PIEZAS DE REPUESTO
TECHNOLOGY 175-210

23

12
22

13
25

21

24

15 11 3 17 5 6 10 2 16 18 4 7 8 9

26 27 28 20 14 19
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;

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 TECHNOLOGY 175-210-188CE/GE
ELENCO PEZZI DI RICAMBIO ELENCO PEZZI DI RICAMBIO ELENCO PEZZI DI RICAMBIO ELENCO PEZZI DI RICAMBIO ELENCO PEZZI DI RICAMBIO
PIECES DETACHEES PIECES DETACHEES PIECES DETACHEES PIECES DETACHEES PIECES DETACHEES
REF. SPARE PARTS LIST REF. SPARE PARTS LIST REF. SPARE PARTS LIST REF. SPARE PARTS LIST REF. SPARE PARTS LIST
ERSATZTEILLISTE ERSATZTEILLISTE ERSATZTEILLISTE ERSATZTEILLISTE ERSATZTEILLISTE
PIEZAS DE REPUESTO PIEZAS DE REPUESTO PIEZAS DE REPUESTO PIEZAS DE REPUESTO PIEZAS DE REPUESTO
Potenziometro Rele' Induttanza Kit Scheda Completa
Potentiometre Relais Inductance Kit Platine Complete
1 Potentiometer 10 Relais 19 Inductance 28 Complete Control Pcb Kit
Potentiometer Relais Drossel Komplette Steurungskarte Kit
Potenciometro Relais Induccion Kit Tarjeta De Controlo Completa
Resistenza Interruttore Trasformatore Potenza
Resistance Interrupteur Transformateur Puissance
2 Resistor 11 Switch 20 Power Transformer
Wiederstand Schalter Leistungstransformator
Resistencia Interruptor Transformador De Potencia
Condensatore Manopola Potenziometro Frontale
Condensateur Poignee Pour Potentiometre Partie Frontal
3 Capacitor 12 Knob For Potentiometer 21 Front Panel
Kondensator Potentiometergriff Geraetefront
Capacitor Malja Por Resist.electr.variable Frontal
Diodo Deviatore Retro
Diode Gareur Partie Arriere
4 Diode 13 Switch 22 Back Panel
Diode Schalter Rueckseite
Diodo Interruptor Trasera
Raddrizzatore Termostato Manico
Redresseur Thermostat Poignee
5 Rectifier 14 Thermostat 23 Handle
Gleichrichter Thermostat Handgriff
Rectificador Termostato Manija
Resistenza Cavo Alim. Presa Dinse
Resistance Cable Alim. Prise Dix
6 Resistance 15 Mains Cable 24 Dinse Socket
Widerstand Netzkabel Dinse Steckdose
Resistencia Cable Alim. Enchufe Dinse
Scheda Controllo Ventilatore Kit Mantello
Carte Controle Ventilateur Kit Capot
7 Control Board 16 Fan 25 Cover Kit
Steuerungskarte Ventilator Deckel Kit
Tarjeta Control Ventilador Kit Panel De Cobertura
Bjt Tip50 Induttanza Filtro Kit Fondo
Bjt Tip50 Inductance Filter Kit Chassis
8 Bjt Tip50 17 Filter Inductance 26 Bottom Kit
Bjt Tip50 Filter Drossel Bodenteil Kit
Bjt Tip50 Induccion Filtro Kit Fondo
Bjt Tip122 Trasformatore Ausiliario Kit Igbt + Diodo
Bjt Tip122 Transformateur Auxiliaire Kit Igbt + Diode
9 Bjt Tip122 18 Auxiliary Transformer 27 Kit Igbt + Diode
Bjt Tip122 Hilfstransformator Kit Igbt + Diode
Bjt Tip122 Transformador Auxiliar Kit Igbt + Diodo

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!

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 TECHNOLOGY 175-210-188CE/GE
ELENCO PEZZI DI RICAMBIO - LISTE PIECES DETACHEES
SPARE PARTS LIST - ERSATZTEILLISTE - PIEZAS DE REPUESTO
TECHNOLOGY 188CE/GE

23

12
22

13
25

21

24

15 11 3 17 5 6 10 2 16 18 4 7 8 9 29

26 27 28 20 14 19

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.

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 TECHNOLOGY 175-210-188CE/GE
ELENCO PEZZI DI RICAMBIO ELENCO PEZZI DI RICAMBIO ELENCO PEZZI DI RICAMBIO ELENCO PEZZI DI RICAMBIO ELENCO PEZZI DI RICAMBIO
PIECES DETACHEES PIECES DETACHEES PIECES DETACHEES PIECES DETACHEES PIECES DETACHEES
REF. SPARE PARTS LIST REF. SPARE PARTS LIST REF. SPARE PARTS LIST REF. SPARE PARTS LIST REF. SPARE PARTS LIST
ERSATZTEILLISTE ERSATZTEILLISTE ERSATZTEILLISTE ERSATZTEILLISTE ERSATZTEILLISTE
PIEZAS DE REPUESTO PIEZAS DE REPUESTO PIEZAS DE REPUESTO PIEZAS DE REPUESTO PIEZAS DE REPUESTO
Potenziometro Rele' Induttanza Kit Scheda Completa
Potentiometre Relais Inductance Kit Platine Complete
1 Potentiometer 10 Relais 19 Inductance 28 Complete Control Pcb Kit
Potentiometer Relais Drossel Komplette Steurungskarte Kit
Potenciometro Relais Induccion Kit Tarjeta De Controlo Completa
Resistenza Interruttore Trasformatore Potenza Induttanza Filtro Ge
Resistance Interrupteur Transformateur Puissance Inductance Filter Ge
2 Resistor 11 Switch 20 Power Transformer 29 Ge Filter Inductance
Wiederstand Schalter Leistungstransformator Ge Filter Drossel
Resistencia Interruptor Transformador De Potencia Induccion Filtro Ge
Condensatore Manopola Potenziometro Frontale
Condensateur Poignee Pour Potentiometre Partie Frontal
3 Capacitor 12 Knob For Potentiometer 21 Front Panel
Kondensator Potentiometergriff Geraetefront
Capacitor Malja Por Resist.electr.variable Frontal
Diodo Deviatore Retro
Diode Gareur Partie Arriere
4 Diode 13 Switch 22 Back Panel
Diode Schalter Rueckseite
Diodo Interruptor Trasera
Raddrizzatore Termostato Manico
Redresseur Thermostat Poignee
5 Rectifier 14 Thermostat 23 Handle
Gleichrichter Thermostat Handgriff
Rectificador Termostato Manija
Resistenza Cavo Alim. Presa Dinse
Resistance Cable Alim. Prise Dix
6 Resistance 15 Mains Cable 24 Dinse Socket
Widerstand Netzkabel Dinse Steckdose
Resistencia Cable Alim. Enchufe Dinse
Scheda Controllo Ventilatore Kit Mantello
Carte Controle Ventilateur Kit Capot
7 Control Board 16 Fan 25 Cover Kit
Steuerungskarte Ventilator Deckel Kit
Tarjeta Control Ventilador Kit Panel De Cobertura
Bjt Tip50 Induttanza Filtro Kit Fondo
Bjt Tip50 Inductance Filter Kit Chassis
8 Bjt Tip50 17 Filter Inductance 26 Bottom Kit
Bjt Tip50 Filter Drossel Bodenteil Kit
Bjt Tip50 Induccion Filtro Kit Fondo
Bjt Tip122 Trasformatore Ausiliario Kit Igbt + Diodo
Bjt Tip122 Transformateur Auxiliaire Kit Igbt + Diode
9 Bjt Tip122 18 Auxiliary Transformer 27 Kit Igbt + Diode
Bjt Tip122 Hilfstransformator Kit Igbt + Diode
Bjt Tip122 Transformador Auxiliar Kit Igbt + Diodo

Scheda tecnica di riparazione:

Con lo scopo di migliorare il servizio, alla fine di ogni riparazione chiediamo ad ogni Centro Assistenza di compilare
e restituire a Telwin la scheda tecnica riportata nella pagina seguente.
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 TECHNOLOGY 175-210-188CE/GE

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 Component ref.

Substitution of primary power board: yes no
Rectifier bridge
Electrolytic capacitors Troubles evinced during repair :
Relais
In-rush limiter resistance
IGBT
Snubber
Secondary diodes
Potentiometer
Others
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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