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Tecnica 141 - 161
Tecnica 141 - 161
988584
TROUBLESHOOTING
AND REPAIR MANUAL
CONTENTS PAGE
REPAIR GUIDE.......................................................10
Equipment required 10
General repair instructions 11
Troubleshooting and remedies 11
Testing the machine 14
Illustrations 16
REPAIR SHEET...................................................... 19
“reparation
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INPUT PRIMARY PRE-CHARGE RECTIFIER BRIDGE FILTER CHOPPER CURRENT POWER SECONDARY INDUCTANCE EMC FILTER I I° OUTPUT
EMC FILTER TRANSFORMER TRANSFORMER DIODES
1 2 3 4 5 6 7 8 9 10
BLOCK DIAGRAM
25 24 11 12 13 17 19
-2-
DUTY CYCLE ADDER ALARM BLOCK CURRENT
MAKER POTENTIOMETER
TECNICA 141 - 161
14 15 16 18
UNDERVOLTAGE
SAFEGUARD CONTROL
23
20 21 22
OPERATION AND WIRING DIAGRAMS
TECNICA 141 - 161
ANALYSIS OF THE BLOCK DIAGRAM
Block 9
NOTE: Unless indicated otherwise, it should be assumed that Inductance
the components are assembled on the power board. Consisting of: L2.
Levels the secondary board diodes’ output current making it
practically continuous.
Block 1
EMC Filter Block 10
Consisting of: C1, L1, C5, C6. Secondary EMC Filter
Prevents noise from the machine from being transmitted along Consisting of: C31, C32.
the main power line and vice versa. Prevents noise from the power source from being transmitted
through the welding cables and vice versa.
Block 2
Pre-charge Block 11
Consisting of: K1, R1. Flyback power supply
Prevents the formation of high transitory currents that could Consisting of: T1, U2.
damage the main power switch, the rectifier bridge and the Uses switching methods to transform and stabilise the voltage
electrolytic capacitors. obtained from block 4 (filter) and supplies auxiliary voltage to
When the power source is switched on the relay K1 is de- power block 12 (driver) and the control board correctly.
energised, capacitors C2, C3, C4 are then charged by R1.
When the capacitors are charged the relay is energised. Block 12
Driver
Block 3 Consisting of: ISO2, ISO3.
Rectifier bridge Takes the signal from block 11 (flyback power supply) and,
Consisting of: D1. controlled by block 14 (duty cycle maker), makes the signal
Converts the mains alternating voltage into continuous pulsed suitable for piloting block 6 (chopper).
voltage.
Block 13
Block 4 Primary current reader and limiter
Filter Consisting of: R20, R37, R38 and part of the control section.
Consisting of: C2, C3, C4. Reads the signal from block 6 (current transformer) and scales
Converts the pulsed voltage from the rectifier bridge into it down so it can be processed and compared in blocks 14 and
continuous voltage. 15.
Block 14
Block 5 Duty cycle maker
Chopper Consisting of: U2 (control board).
Consisting of: Q1, Q2. Processes the information from block 15 (adder) and block 13
Converts the continuous voltage from the filter into a high (primary current reader and limiter) and produces a square
frequency square wave capable of piloting the power wave with variable duty cycle limiting the primary current to a
transformer. maximum pre-set value under all circumstances.
Regulates the power according to the required welding
current/voltage. Block 15
Adder
Block 6 Consisting of: U1C (control board).
Current transformer Gathers all the information from block 13 (primary current
Consisting of: T2. reader and limiter), from block 16 (alarms) and from block 18
The C.T. is used to measure the current circulating in the (current potentiometer), and produces a signal with a suitable
power transformer primary and transmit the information to voltage for processing by block 14 (duty cycle maker).
block 14 (primary current reader and limiter).
Block 16
Block 7 Alarm Block
Power transformer Consisting of: U1A, U1B (control board).
Consisting of: T3. When an alarm is detected the power source output current is
Adjusts the voltage and current to values required for the drastically reduced by making direct adjustments to block 14
welding procedure. Also forms galvanic separation of the (duty cycle maker) and directly changing the reference signal
primary from the secondary (welding circuit from the power obtained from block 18 (current potentiometer).
supply line).
Block 17
Block 8 Alarm LED
Secondary diodes Consisting of: D26.
Consisting of: D21, D22, D23 . It is switched on by block 16 (alarms) in the event of:
D21 converts the current circulating in the transformer to a 1) Triggering of thermostatic capsule/thermostat on power
single direction, preventing saturation of the nucleus. transformer.
D22, D23 recirculate the inductance output current (block 9) 2) Triggering due to undervoltage.
when the IGBT's are not conducting, bypassing the power 3) Triggering due to overvoltage.
transformer (block 7). 4) Short circuit at output (electrode holder clamp and earth
cable connected to one another or electrode stuck to piece
being welded).
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TECNICA 141 - 161
Block 18
Current potentiometer
Consisting of: R7.
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 19
Maximum current adjustment
Consisting of: R32, R33, R42.
Used to adjust the maximum cutting current to be supplied by
the power source.
Block 20
Power transformer thermostat
Consisting of: ST1.
When the temperature of the power transformer is too high,
this safeguard is triggered. It is reset automatically after the
alarm condition has ceased.
Block 21
Galvanic separator
Consisting of: ISO1.
The signal arriving from block 20 (power transformer
thermostat) is separated galvanically and sent to block 16
(alarms) for detection of a possible alarm event.
Block 22
Overvoltage safeguard
Consisting of: R3, R4 and part of the control section.
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 23
Undervoltage safeguard
Consisting of: R5, R6 and part of control board.
If the main supply voltage falls below the minimum allowed
value this safeguard triggers (a tolerance of approx. ±15% of
the power supply voltage is allowed: outside this range the
safeguard triggers).
Block 24
Power supply LED
Consisting of: D2.
Indicates when the power source is correctly powered and
ready for use.
Block 25
Fan
Consisting of: V1.
Powered directly by block 11 (flyback transformer) and cools
the power components.
(11)
FLY-BACK
(1) (3) POWER SUPPLY (7)
PRIMARY EMC RECTIFIER (2) POWER
FILTRE BRIDGE PRE-CHARGE TRANSFORMER
CONTROL
BOARD
(18)
CURRENT
POTENTIOMETER
(24)
POWER
SUPPLY
LED
(17)
ALARM
LED
(21)
GALVANIC
(4) SEPARATION
FILTER
(10)
SECONDARY
FILTER EMC
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.
B) Please read the procedure for replacing the secondary 1.2 Tests for the TECNICA 141
board diodes carefully (fig. 4): A) Intermediate load test:
The 3 SECONDARY DIODES are attached to the same - set up the static load generator with the switch settings as in
dissipator, and when a replacement is required, all of them the table in fig. D;
should be replaced: - on the front panel position the current potentiometer R7
- undo the screws attaching the dissipator to the board, to about half range and switch on the main switch;
replace diodes D21, D22 and D23; - activate the statico load generator and make sure that:
- remove the 3 secondary diodes unsoldering the rheofores - the waveforms displayed on the oscilloscope resemble
and cleaning any solder from the bump contacts on the those in Fig. D;
board; - the output current is +60Adc±10%, and the output
- remove the dissipator from the board; voltage is +22.4Vdc±10%
- remove the spring locking the 3 diodes; - deactivate the static load generator and switch off the main
- clean any irregularity or dirt from the dissipator. If the diodes switch.
have burst the dissipator may have been irreversibly
damaged: in this case it should be replaced; FIGURE D
- apply thermo-conductive grease following the general
SETTINGS:
instructions; · PROBE CH1 x100
- insert the new diodes between the dissipator and the · 100V/Div;
· PROBE CH2 x10;
spring, taking care not to damage the component during · 2V/Div;
assembly (the screw should be inserted under pressure on · 5 µsec/Div.
the dissipator so as to lock the component); TIME TOLLERANCES
- place the dissipator with the new components in the PCB ±20%.
bump contacts and fasten them down with the screws VERIFY THAT
(torque wrench setting for screws 1 Nm ±20%); · AMPLITUDE CH1
- solder the terminals taking care not to let the solder run IS 320V ±10%.
· AMPLITUDE CH2
along them; IS 5V ±10%.
- on the soldering side cut away the protruding part of the
rheofores and check they are not shorted (between
cathode and anode);
N.B. make sure resistor (R31) and capacitor (C30) on the
snubber have been soldered to the PCB correctly (fig. 3). 1 2 3 4 5 6 Switch number
2 2 2 2 1 0 Position of switch
C) Please read the procedure for replacing the control
board (fig. 3):
B) Rated load test:
Whatever fault occurs in the control board, we strongly
- set up the static load generator with the switch settings as in
recommend its replacement without attempts at repair. To
the table in fig. E;
remove it, cut and then unsolder from the power board the
- on the front panel position the current potentiometer R7 to
connector keeping it fixed perpendicular to the PCB, replace it
the maximum (turn the knob clockwise as far as it will go)
and re-solder the connector.
and switch on the main switch;
- activate the static load generator and make sure that:
TESTING THE MACHINE - the voltage waveforms on the oscilloscope display
resemble those in fig. E;
Tests should be carried out on the assembled machine before - the output current is +120Adc±5%, and the output
closing it with the top cover. During tests with the machine in voltage is +24.8Vdc±5%.
operation never commute the selectors or activate the ohmic - deactivate the static load generator and switch off the main
load contactor. switch.
WARNING! Before proceeding to test the machine, we should
remind you that during these tests the power source is
powered and therefore the operator is exposed to the danger
of electric shock.
The tests given below are used to verify power source
operation under 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).
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TECNICA 141 - 161
FIGURE E 1.3 Tests for the TECNICA 141
In this case the tests are exactly the same as for the Tecnica
SETTINGS: 141 and can be carried out in the same way with the exception
· PROBE CH1 x100
· 100V/Div; of the following points in section 1.2:
· PROBE CH2 x10; - replace point B) with point A) in section 1.3);
· 5V/Div;
· 5µsec/Div.
- in points C) and D) replace the load in fig. E with the load
given in fig. G in section 1.3.
TIME TOLLERANCES
±20%.
A) Rated load test:
VERIFY THAT - set up the static load generator with the switch settings as in
· AMPLITUDE CH1
IS 320V ±10%; the table in fig. G;
· AMPLITUDE CH2 - on the front panel position the current potentiometer R7 to
IS 10V ±10%.
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
1 2 3 4 5 6 Switch number resemble those in fig. G;
3 3 2 2 2 2 Position of switch - the output current is +150Adc±5%, and the output
voltage is +26Vdc±5%.
- deactivate the static load generator and switch off the main
C) Checking the secondary diode voltages: switch.
- set up the dual trace oscilloscope, connecting probe CH1 x
100 to the anode of diode D21 and probe CH2x100 to the FIGURE G
anode of diode D22. Earth connections are both made to SETTINGS:
the secondary dissipator; · PROBE CH1 x100
· 100V/Div;
- remove the multimeter from the OUT+ and OUT- bump · PROBE CH2 x10;
contacts; · 5V/Div;
· 5µsec/Div.
- set up the static load generator with the switch settings as
in the table in fig. E; TIME TOLLERANCES
±20%.
- on the front panel position the current potentiometer R7 to
the maximum (turn the knob clockwise as far as it will go) VERIFY THAT
and switch on the main switch; · AMPLITUDE CH1
IS 320V ±10%;
- activate the static load generator and make sure that the · AMPLITUDE CH2
waveforms displayed on the oscilloscope resemble those IS 10V ±10%.
in fig. F;
- deactivate the static load generator and switch off the main
switch.
1 2 3 4 5 6 Switch number
FIGURE F
3 3 3 3 2 1 Position of switch
SETTINGS:
· PROBE CH1 x100;
· 50V/Div
B) Running time check and closing the machine
· PROBE CH2 x100; With the load status as in fig. G and the cutting current
· 50V/Div;
· 5µsec/Div.
adjustment potentiometer (R42) on maximum, switch on the
power source and leave it in operation until the thermostatic
TIME TOLLERANCES capsules trigger (machine in alarm status). Check the correct
±20%.
positioning of the internal wiring and finally re-assemble the
VERIFICARE CHE: machine.
VERIFY THAT:
REVERSE AMPLITUDE
ON CH1 E CH2 DOES
NOT EXCEED 250V.
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.
CURRENT REGULATION
SCREWS FASTENING POTENTIOMETER
HANDLE
SCREWS FASTENING
BACK PANEL ALARM LED
DINSE SOCKET
SCREWS FASTENING
TOP COVER SCREWS
FASTENING FRONT PANEL
FIG. 2A FIG. 2B
BUMP BUMP
CONTACTS CONTACTS RHEOFORES RHEOFORES
POWER SUPPLY FILTER POWER FAN WIRE POWER THERMOSTAT FAN Q2 D14
INTERRUPTOR CAPACITORS TRANSFORMER BOARD ST1 J5
DIODES BRIDGE
DISSIPATOR
Q2
DISSIPATOR
SCREWS
FASTENING
Q1
DISSIPATOR
SCREWS
FASTENING
C2
LED
D2
LED
R21 D26
R27 ISO1
R31 E
C30
21 22
18
7
16
20
12 2 25 3 14 23 24
19
8
1
6
10
5 13
17
15 11 4
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Supply:
Power supply
From mains without extension
From mains with extension m:
Dirty grade
Dirty inside the machine
Description: