cod.

988588

TECHNOLOGY 150-170-200-186CE/GE
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.......................................................10
Equipment required 10
General repair instructions 11
Troubleshooting and remedies 11
Testing the machine 14
Illustrations 17

SPARE PARTS LIST...............................................20

REPAIR SHEET...................................................... 22

reparation no problem !
 INPUT PRIMARY RECTIFIER PRE-CHARGE FILTER CHOPPER CURRENT POWER SECONDARY INDUCTANCE & SECONDARY OUTPUT
EMC FILTER BRIDGE TRANSFORMER TRANSFORMER DIAODES SHUNT FILTER EMC

+
-

1 2 3 4 5 6 7 8 9 10

BLOCK DIAGRAM
FAN OVERVOLTAGE UNDERVOLTAGE FLY-BACK IGBT DRIVER PRIMARY CURRENT MAXIMUN SHUNT
SAFEGUARD SAFEGUARD POWER SUPPLY READER AND LIMITER CURRENT AMPLIFIER
REGULATOR
V

+
V

|
t t

27 25 26 11 12 13 21 20

ALARM LED ALARM BLOCK DUTY CYCLE ADDER CURRENT

FORMATOR POTENTIOMETER

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17 16 14 15 18

SECONDARY INDUCTANCE GALVANIC SHORT CIRCUIT ARC FORCE HOT START WELDING MODE
DIODES THERMOSTAT SEPARATION DELAY FUNCTION
THERMOSTAT i i SELECTOR

TIG-LIFT

HARD SOFT
t t
22 23 24 31 30 29 19

SHORT CIRCUIT
DETECTOR
V

t
HYBRID 28
OPERATION AND WIRING DIAGRAMS
TECHNOLOGY 150-170-200-186CE/GE
TECHNOLOGY
TECHNOLOGY 150-170-200-186CE/GE
150-170-200-186CE/GE
ANALYSIS OF THE BLOCK DIAGRAM - D3, D5 recirculate the inductance output current (block 9)
NOTE: Unless indicated otherwise, it should be assumed that during the time when the IGBT's are not conducting,
the components are assembled on the welding machine. bypassing the power transformer (block 7).

Block 1
EMC Filter
Consisting of: C3, R5, L1, C8, C9 (primary board).
Prevents noise from the machine from being transmitted along
the main power line and vice versa.
Block 2
Rectifier bridge
Consisting of: D3, D5 (primary board).
Converts the alternating mains voltage to continuous pulsed
voltage (N.B. No D3 present on Technology 150).
Block 3
Pre-charge
Consisting of: K1, K2, R1 (primary board).
Prevents the formation of high transient currents that could
damage the main switch, the rectifier bridge and the
electrolytic capacitors. When the power source is switched on
relays K1 and K2 are de-energised, capacitors C2, C4, C5, C6,
C7 are therefore charged via R1. When the capacitors are
charged the relay will be energised. (N.B. No K2 present on
Technology 150).
Block 4
Filter
Consisting of: C2, C4, C5, C6, C7 (primary board).
Converts the pulsed voltage arriving from the rectifier bridge
to continuous voltage (N.B. No C7 present on Technology
150).
Block 5
Chopper
Consisting of: Q1, Q2, Q3, Q4 (primary board).
Converts the continuous voltage from the filter into a high
frequency square wave capable of piloting the power
transformer.
Regulates the power according to the required welding
current/voltage.
Block 6
Current transformer
Consisting of:T1 (primary board).
The C.T. is used to measure the current circulating in the power
transformer primary and transmit the information to block 14
(primary current reader and limiter).
Block 7
Power transformer
Consisting of:T1.
Adjusts the voltage and current to values required for the
welding procedure. Also forms galvanic separation of the
primary from the secondary (welding circuit from the power
supply line).
Block 8
Secondary diodes
Consisting of: D1, D2, D3, D5(secondary board).
- D1 and D2 convert the current circulating in the transformer
to a single direction, preventing saturation of the nucleus.
(N.B.: No D2 on Technology 150).
Block 9
Inductance and Shunt
Consisting of: L1, R1.
The inductance levels the output current from the secondary
board diodes making it practically direct.The shunt detects the
current circulating in the secondary and sends a voltage signal
to block 16 (adder), which will process it.
Block 10
Secondary EMC Filter
Consisting of: CY1, CY2.
Prevents noise from the power source from being transmitted
through the welding cables and vice versa.
Block 11
Flyback power supply
Consisting of:T2, U2 (primary board).
Uses switching methods to transform and stabilise the voltage
obtained from block 4 (filter) and supplies auxiliary voltage to
power block 12 (driver) and the hybrid board.
Block 12
IGBT Driver
Consisting of: U1A, U1D (primary board).
Takes the signal from block 11 (flyback power supply) and,
controlled by block 14 (duty cycle maker), makes the signal
suitable for piloting block 6 (chopper).
Block 13
Primary current reader and limiter
Consisting of: R15 (primary board).
Reads the signal from block 6 (current transformer) and scales
it down so it can be processed and compared in block 14 (duty
cycle maker).
Block 14
Duty cycle maker
Consisting of: U2 (hybrid board).
Processes the information from block 15 (adder) and block 13
(primary current reader and limiter) and produces a square
wave with variable duty cycle limiting the primary current to a
maximum pre-set value under all circumstances.
Block 15
Adder
Consisting of: U1A, U1D (hybrid board).
Gathers all the information from block 13 (primary current
reader and limiter), from block 16 (alarms) and from block 18
(current potentiometer), and produces a signal with a suitable
voltage for processing by block 14 (duty cycle maker).
Block 16
Alarm Block
Consisting of: Q5, R11, R14, R17 (control board).
When an alarm is detected the power source output current is
drastically reduced by making direct adjustments to block 14
(duty cycle maker) and directly changing the reference signal
obtained from block 18 (current potentiometer).

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 TECHNOLOGY 150-170-200-186CE/GE
Block 17 Block 25
Alarm LED Overvoltage safeguard
Consisting of: D9 (primary board). Consisting of: U3A, R62, R68 (primary board).
It is switched on by block 16 (alarms) in the event of: If the main supply voltage exceeds the maximum value this
1) Triggering of thermostatic capsule on inductance. safeguard triggers (a tolerance of approx. 15% of the power
2) Triggering of thermostatic capsule on secondary diodes. supply voltage is allowed: outside this range the safeguard
3) Triggering due to undervoltage. triggers).
4) Triggering due to overvoltage.
5) Short circuit at output (electrode holder clamp and earth Block 23
cable connected to one another or electrode stuck to piece Undervoltage safeguard
being welded). Consisting of: U3B, R61, R67(primary board).
Block 18 If the main supply voltage falls below the minimum allowed
Current potentiometer value this safeguard triggers (a tolerance of approx. 15% of
Consisting of: R16 (primary board). the power supply voltage is allowed: outside this range the
This is used to set the reference voltage needed to adjust the safeguard triggers).
output current: when the potentiometer knob is turned the
cursor voltage varies, thus varying the current from the Block 27
minimum to the maximum value. Fan
Consisting of:V1.
Block 19 Powered directly 230V by block 11 (flyback transformer) and
Welding mode function selector cools the power components.
Consisting of: SW1 (primary board)
The switch is used to select the type of welding procedure: Block 28
TIG-Lift, Hard or Soft. Short circuit detector
Consisting of: U3B (hybrid board).
Block 20 If the welding voltage is below 10V this circuit causes block 30
Shunt Amplifier (arc force) to trigger.
Consisting of: U4 (hybrid board)
Amplifies the signal arriving from block 10 (shunt
inductance), making it suitable for block 21 (maximum Block 29
current regulator). Hot Start
Consisting of: Q2,Q3,C9 (hybrid board).
Block 21 At the start of MMA welding, Hot Start generates a temporary
Maximum current regulator overcurrent based on the current setting made by block 20
Consisting of: R13 (primary board) (current potentiometer) in order to pre-heat the electrode and
Used to regulate the maximum welding current that can be prepare the weld pool.
supplied by the power source.
Block 30
Block 22 Arc Force
Secondary diode thermostat Consisting of: Q6, Q7, C14 (hybrid board).
Consisting of: ST1 If the arc voltage falls below 10V, this block produces a
When the temperature of the secondary diode dissipator is too temporary increase in the output current, so as to detach the
high the thermostat cuts in, sending an alarm signal to block 24 electrode from the piece after it has become stuck.
(galvanic separation). It is reset automatically when this alarm
condition is no longer present. Block 31
Short circuit delay
Block 23 Consisting of: U3B (hybrid board).
Inductance thermostat If the output shorting persists this block shuts down the
Consisting of: ST2 power source via block 16 (alarms).
When the temperature of the inductance is too high the
thermostat cuts in, sending an alarm signal to block 24
(galvanic separation). It is reset automatically when this alarm
condition is no longer present.

Block 24
Galvanic separation
Consisting of: ISO3 (primary board).
The signals arriving from blocks 22 and 23 (transformer
thermostat and inductance thermostat) are separated
galvanically and sent to block 16 (alarms) for detection of a
possible alarm event.

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150-170-200-186CE/GE
ILLUSTRATIONS
Primary board
(1) (2) (4)
EMC RECTIFIER (19)
FILTER (25-26) FUNCTIONS
FILTER (5) BRIDGE
OVER/UNDER VOLAGE SELECTOR
CHOPPER SAFEGUARD (18)
CURRENT
POTENTIOMETER

(17)
ALARM
LED

(12) (11)
DRIVER (3) HYBRID BOARD FLY-BACK
PRE-CHARGE (24)
IGBT (5) (6) GALVANIC POWER SUPPLY
CHOPPER CURRENT SEPARATION
TRASFORMER

Secondary board

(8) (9) (10)

SECONDARY DIODES SHUNT SECONDARY
EMC FILTER

(8) (22)
SECONDARY DIODES SECONDARY DIODES
THERMOSTAT

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 TECHNOLOGY 150-170-200-186CE/GE
WIRING DIAGRAMS
General wiring diagram

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TECHNOLOGY
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Wiring diagram primary board - Power

Schema elettrico scheda primario - Driver

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 TECHNOLOGY 150-170-200-186CE/GE
Wiring diagram primary board - Power supply

Wiring diagram primary board - Driver

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Wiring diagram hybrid board

Wiring diagram secondary board

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 TECHNOLOGY 150-170-200-186CE/GE

REPAIR GUIDE
EQUIPMENT REQUIRED

1 7 6 3 2 8

4 5 9

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
5 Differential probe 1/200
6 Hall Probe cod. 802406 (*)
7 HV Power supply cod. 802403 (*)

USEFUL INSTRUMENTS
8 Unsoldering station
9 Miscellaneous tools

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

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TECHNOLOGY
TECHNOLOGY 150-170-200-186CE/GE
150-170-200-186CE/GE
GENERAL REPAIR INSTRUCTIONS
The following is a list of practical rules which must be strictly
WARNING: adhered to if repairs are to be carried out correctly.
A) When handling the active electronic components, the IGBT's
BEFORE PROCEEDING WITH REPAIRS TO and Power DIODES in particular, take elementary antistatic
THE MACHINE READ THE INSTRUCTION precautions (use antistatic footwear or wrist straps, antistatic
MANUAL CAREFULLY. working surfaces etc.).
B) To ensure the heat flow between the electronic components
and the dissipator, place a thin layer of thermo-conductive
WARNING: grease (e.g. COMPOUND GREASIL MS12) between the
contact zones.
EXTRAORDINARY MAINTENANCE SHOULD C) The power resistors (should they require replacement) should
BE CARRIED OUT ONLY AND EXCLUSIVELY always be soldered at least 3 mm above the board.
BY EXPERT OR SKILLED ELECTRICAL- 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
MECHANICAL PERSONNEL. reticulating silicones (e.g. DOW CORNING 7093). Otherwise,
silicone that is placed in contact with points at different
WARNING: potential (rheophores of IGBT's, etc.) should be left to
reticulate before the machine is tested.
ANY CHECKS CARRIED OUT INSIDE THE E) When the semiconductor devices are soldered the maximum
MACHINE WHEN IT IS POWERED MAY CAUSE temperature limits should be respected (normally 300C for no
more than 10 seconds).
SERIOUS ELECTRIC SHOCK DUE TO DIRECT F) It is essential to take the greatest care at each disassembly
CONTACTWITH LIVE PARTS. 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
HV POWER SUPPLY MODULE in the reverse order when re-assembling (damaged parts
should never be omitted but should be replaced, referring to
THE HV POWER SUPPLY is used to ensure operation of the the spare parts list given at the end of this manual).
switching power supply (the circuit on the primary board supplying H) The boards (repaired when necessary) and the wiring should
auxiliary voltages), even when the machine is operating at low never be modified without prior authorisation from Telwin.
voltage. I) For further information on machine specifications and
It is easy to build using the electrical diagrams in fig. A for operation, refer to the Instruction Manual.
reference and using the following components or, alternatively, it J) WARNING! When the machine is in operation there are
can be ordered from Telwin. dangerously high voltages on its internal parts so do not touch
the boards when the machine is live.
T1 = insulation transformer 230-230V 50VA(*)
D1 = rectifier bridge 36MB 80 (cod. 112357)
C1 = electrolytic capacitor 470uF 400V ALL TROUBLESHOOTING AND REMEDIES
(cod.112514)
R1 = resistor 10 ohm 5W 5%
R2 = resistor 100K ohm 2W 5% 1.0 Disassembling the machine
F1 = delayed action fuse 1.5 A Fuse holder 5X20mm WARNING! Every operation should be carried out in complete
Female red and black faston safety with the power supply cable disconnected from the mains
Plastic box. outlet:
- Undo the 8 screws fastening the 2 plastic covers (4 each) to the
FIGURE A front and back (figure 1A).
- Undo the 8 screws fastening the top cover to the structure
ELECTRICAL DIAGRAM FOR POWER SUPPLY (HV OUTPUT):
(figure 1B).
- Slide out the top cover by pulling gently outwards (figure 1B).
F1 R1 After completing the repairs, proceed in the reverse order to re-
T1 10 5 assemble the cover and do not forget to insert the toothed washer
on the ground screw.
D1
2.0 Cleaning the inside of the machine
R2 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.
THE INSULATION TRANSFORMER CAN BE REPLACED WITH To clean the electronic boards we advise decreasing the air
T WO T R A N S F O R M E R S O F T H E S A M E P OW E R , pressure to prevent damage to the components.
CONNECTING THE SECONDARIES ACCORDING TO THE It is therefore important to take special care when cleaning the
following parts
FOLLOWING DIAGRAM:
Fan (fig. 2B)
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.
Primary board (fig. 3:)
- rheofores of IGBT's Q1, Q2, Q3, Q4;
- rheofores of recirculating diodes D4, D8;
- rheofores of snubber network diodes D1, D6;

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 TECHNOLOGY 150-170-200-186CE/GE
- rheofores of opto-couplers ISO1 and ISO2; 4.0 Checking the power and signal wiring
- rheofores of connectors J4 and J6; It is important to check that all the connections are in good
Secondary board (fig. 4):) condition and the connectors are inserted and/or attached
- rheofores of secondary power diodes D1, D2, D3, D5 (N.B. not correctly. To do this, take the cables between finger and thumb (as
present on Technology 150); close as possible to the fastons or connectors) and pull outwards
- thermostat ST1 on secondary diode dissipator; gently: the cables should not come away from the fastons or
- shunt R1. connectors. N.B. If the power cables are not tight enough this could
Power transformer and inductance assembly cause dangerous overheating.
Do this if it is necessary to remove the primary board, otherwise it
is possible to clean the part superficially from the side of the 5.0 Electrical measurements with the machine
secondary board. switched off
Parts fastened to the base A) With the multimeter set on diode testing check the following
If the primary and secondary boards are removed (with the components (joint voltages not less than 0.2V):
diaphragm), carefully clean all the parts fastened to the base, or - rectifier bridges D3, D5 (fig. 3);
clean the base partially from the sides of the machine. - IGBT's Q1, Q2, Q3, Q4, (no short circuits between collector-
gate and collector-emitter (fig. 3);
3.0 Visual inspection of the machine - secondary diodes D1, D2, D3, D5 between anode and
Make sure there is no mechanical deformation, dent, or damaged cathode (fig. 4). The secondary diodes can be tested without
and/or disconnected connector. removing the primary board, placing a prod on the secondary
Make sure the power supply cable has not been damaged or diode dissipator and the other in sequence on the 2 power
disconnected internally and that the fan works with the machine transformer output terminals.
switched on. Inspect the components and cables for signs of B) With the multimeter in ohm mode check the following
burning or breaks that may endanger operation of the power components:
source. Check the following elements: - resistor R1: 47 ohm (precharge fig. 3).
Current potentiometer R16 (fig. 3) - resistors R2, R6: 10 ohm (primary snubber fig. 3).
Probable cause: - resistor R1: 10 ohm (secondary snubber fig. 4).
- mechanical shock. - thermostat continuity test on inductance and secondary
Relays K1, K2 primary board (fig. 3) dissipator: disconnect connector J2 from the primary board
Probable cause: and make sure the resistance between pins 4 and 5 is approx.
- see main power supply switch. N.B. If the relay contacts are 0ohm (fig. 4).
stuck together or dirty, do not attempt to separate them and
clean them, just replace the relay.
Electrolytic capacitors C2,C4,C6,C7 primary board (fig. 3) 6.0 Electrical measurements with the machine in
Probable cause: operation
- mechanical shock; WARNING! Before proceeding with faultfinding, we should remind
- machine connected to power supply voltage much higher than you that during these tests the power source is powered and
the rated value; therefore the operator is exposed to the danger of electric shock.
- broken rheophore on one or more capacitor: the remainder will The tests described below can be used to check the operation of
be overstressed and become damaged by overheating; the power and control parts of the power source.
- ageing after a considerable number of working hours;
- overheating caused by thermostatic capsule failure. 6.1 Preparation for testing
IGBT's Q1, Q2, Q3, Q4 primary board (fig. 3) A) From the primary board, disconnect fastons CN3 (XF+) and
Probable cause: CN10 (XF-) for the power transformer (fig. 3).
- discontinuation in snubber network, B) On the primary board disconnect the jumper on JP1.
- fault in driver circuit C) Connect the HV power supply OUT (code 802403) on the
- poorly functioning thermal contact between IGBT and primary board as follows (fig. 3):
dissipator (e.g. loosened attachment screws: check), - (+) Positive (clamp) to rheofore of resistor R35 towards JP1
- excessive overheating related to faulty operation. (after removing jumper JP1);
Primary diodes D1, D4, D6, D8 primary board (fig. 3) - (-) Negative (faston) to negative faston of diode bridge D3.
Probable cause: D) Set up the oscilloscope with the voltage probe x100 connected
- excessive overheating related to faulty operation. between the rheofore of R40B (collector Q10) towards JP1
Mode selector switches SW1 and SW3 primaryboard (probe) and the negative of diode bridge D3 (earth) to the primary
(fig. 3) board (fig. 3).
Probable cause: E) Position the current potentiometer R16 on maximum (turn
- mechanical shock. clockwise as far as it will go) and switch SW1 to SOFT (as far down
Secondary diodes D1, D2, D3, D5 secondary board (fig. 4) as it will go);
Probable cause: WARNING! the high frequency voltage will permanently damage
- discontinuation in snubber network; any instrument connected to the generator. Before proceeding
- poorly functioning thermal contact between IGBT and make very sure that the fastons listed above are disconnected and
dissipator (e.g. loosened attachment screws: check); completely isolated from one another.
- faulty output connection. F) Connect the power supply cable to a single phase variac with
Shunt R1 secondary board (fig. 6) variable output 0-300 Vac.
Check it for colour changes. WARNING! during testing prevent contact with the metal part of
Probable cause: the torch because of the presence of high voltages that are
- overheating due to loosening of the screws connecting the shunt hazardous to the operator.
to the PCB.
Power transformer and filter inductance 6.2 Scheduled tests
Inspect the windings for colour changes. A) Switch on the HV power supply (HV OUT) and make sure that
Probable causes: (fig. 3):
- aging after a substantial number of working hours; - pre-charge relays K1 and K2 close;
- excessive overheating related to faulty operation. - the fan starts to turn for the power transformer;
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TECHNOLOGY
TECHNOLOGY 150-170-200-186CE/GE
150-170-200-186CE/GE
- yellow led alarm is turn off. K) Make sure the waveform shown on the oscilloscope
B) Make sure the waveform shown on the oscilloscope resembles fig. D.
resembles Fig. B.
FIGURE B FIGURE D

SETTINGS: SETTINGS:
PROBE x100; PROBE x100;
100 V/Div; 10V/Div;
10 sec/Div. 10 sec/Div.
VERIFY THAT VERIFY THAT
THE FREQUENCY AMPLITUDE ON
IS 35KHz 15%; CH1 IS 35V 20%;
AMPLITUDE IS
450V 10%;

N.B. if there is no signal it may be necessary to replace the L) Repeat this test on Q2 as well, using the differential probe.
integrated circuit U2 or IGBT Q10 on the primary board (fig. 3). N.B. If the signal is not present there may be a fault in the IGBT's
C) Set up the multimeter in volt mode and make sure the primary (fig.5).
board has the following voltages: (fig. 3): M) Return the variac voltage to 0V, switch off the machine and the
- between the cathode of diode D32 (+) and the negative of diode HV power supply.
bridge D5 (-): equal to +15Vdc 3%; N) Disconnect the HV power supply, replace jumper JP1 on the
- between pin 3 (+) and the dissipator (-) of U4: equal to +12Vdc board.
5%; O) Switch the machine on again and gradually increase the
- between pin 3 (+) and pin 1 (-) of U6: equal to -12Vdc 5%; voltage generated by the variac to 115Vac 5% then make sure an
- between pin 8 (+) and pin 7 (-) of ISO1: equal to +26Vdc 5%; alarm is registered with yellow LED D9 lit up.
- between pin 8 (+) and pin 7 (-) of ISO2: equal to +26Vdc 5%; P) Increase the voltage on the variac to 230Vac and make sure
D) Switch off the HV power supply. the alarm ceases (yellow LED D9 goes off).
E) Set up the oscilloscope with the voltage probe x10 connected Q) Increase the voltage on the variac yet again to 275Vac 5%
between the gate (probe) and the emitter (earth) of IGBT Q4 on and make sure the machine registers an alarm again. Return the
the primary board (fig. 3). variac voltage immediately to 230Vac and switch off the machine.
F) Switch on the HV power supply (HV out) and make sure the N.B. if an alarm persists (and is not caused by a fault in the hybrid
waveform displayed on the oscilloscope resembles fig. C. board) there could be a fault in opto-isolator ISO3 or integrated
circuit U3 on the primary board (fig. 3).
FIGURE C
7.0 Repairs, replacing the boards
If repairing the board is complicated or impossible, it should be
SETTINGS:
PROBE x10;
completely replaced.
10V/Div; The board is identified by a 6-digit code (printed in white on the
10 sec/Div. component side after the initials TW).This is the reference code for
requesting a replacement: Telwin may supply boards that are
VERIFY THAT
POSITIVE AMPLITUDE compatible but with different codes.
IS +18V 10%; WARNING! before inserting a new board check it carefully for
NEGATIVE AMPLITUDE
IS -10V 10%.
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 primary board (fig. 3)

G) Repeat this test on Q1, Q2, Q3 as well.
N.B. if the signal is not present there could be a fault in the IGBT
driver circuit, specifically ISO1 and ISO2 (fig. 3), or in the hybrid
board (fig. 3, in which case we recommend replacing the board).
H) Switch off the HV and replace the 2 fastons connecting the
primary board and the power transformer (CN3 and CN10).
I) Switch on the HV and the variac (initially set to 0V), close the
main power supply switch on the machine and gradually increase
the voltage generated by the variac until it reaches 26Vac.
J) Set up the oscilloscope with the voltage probe x100 connected
between the collector (probe) and the emitter (earth) of IGBT Q4
on the primary board (fig. 3).
If the fault is in the primary board remove it from the machine
structure as follows:
- with the machine disconnected from the main power supply
disconnect all the wiring from the primary board;
- cut any bands restricting the board (e.g. on the power supply
cable and primary connections);
- undo the screws fastening the front and back panels and
remove the panels from the machine structure;
- remove the current adjustment knob on the front panel of the
machine;
- undo the screws fastening the primary board to the machine
structure (fig.2B);
- remove the primary board by lifting it upwards.
N.B. for assembly proceed in the reverse order.

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 TECHNOLOGY 150-170-200-186CE/GE
Please read the procedure for replacing the IGBT's
carefully (fig. 3).
The 4 IGBT's are attached to 2 different dissipators and whenever
a replacement is required, both IGBT's should be replaced.
- Unscrew the four (4) nuts that fix the dissipator onto the card;
- unscrew the four (4) screws that fix the four (4) IGBT onto the
dissipator;
- unscrew the two (2) screws that fix the two diode bridges onto
the dissipator;
- remove the four (4) IGBT and the two (2) diode bridges by
unwelding the reophores, then remove tin from the p r i n t e d
plates;
- remove dissipator from card.
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
st rd
short circuit on the PCB between the 1 and 3 bump contacts
(between gate and emitter) corresponding to each
component;
- alternatively, resistors R3, R4, R7, R8 could have burst and/or
diodes D11, D12, D15, D16 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.
- prepare the components for replacement. For the IGBT's,
bend the rheofores at 90 (never bend and/or place the parts
under tension near the case).
- position the components on the dissipator with the fastening
screws, but do not tighten the screws completely
- join the dissipator/component assembly to the printed board,
inserting all the rheofores in the bump contacts and the
threaded spacers on the 4 attachment holes.
- attach the dissipators with the nuts and lock them once and for
all in the following order:
- the nuts fastening the dissipators to the printed circuit with a
torque wrench setting of 2 Nm 20%;
- the screws fastening the rectifiers to the dissipators with a
torque wrench setting of 2 Nm 20%;
- the screws fastening the IGBT's to the dissipators with a
torque wrench setting of 1 Nm 20%.
- solder the terminals taking care not to let the solder run along
them.
- on the component side cut away the protruding part of the
rheofores and check they are not shorted (especially the gate
and emitter).
NOTE. The 4 IGBT's should belong to the same selection kit
supplied by Telwin.
7.2 Removing the hybrid board (fig. 3)
If the fault is in the hybrid board remove it from the primary board
as follows:
- with the primary board removed from the machine structure
unsolder the rheofores from the hybrid board on the soldering
side;
- remove the solder from the bump contacts on the PCB;
- remove the hybrid board from the primary board;
N.B. for assembly proceed in the reverse order.
If the fault is in the hybrid board we strongly advise replacing it
without further intervention.
7.3 Removing the secondary board (fig. 4)
If the fault is in the secondary board, unless the dissipator has
been damaged by a destructive explosion of the diodes, the board
does not generally need to be removed and the diodes can be
replaced directly with the board mounted on the machine. In any
case, it should be specified that to remove it, it is necessary to
- 14 -
separate the base from the machine structure as follows:
- with the machine disconnected from the main supply undo the 4
side screws (2 on the front and 2 on the back) that attach the
board to the base;
- turn the machine upside down and undo the 2 screws fastening
the base to the structure;
- finally remove the base from the structure.
Complete removal of the secondary board from the structure:
- undo the 4 side screws fastening the board to the machine
structure;
- remove the 3 hexagonal-head screws that fasten the shunt and
connect the power transformer;
- disconnect the wiring for the thermostatic capsule.
N.B. for assembly proceed in the reverse order.
Take special note of the procedure for replacing the
secondary diodes:
The 4 secondary DIODES are attached to the dissipator and
whenever a replacement is made, all 4 diodes should be replaced:
- remove the 4 diodes by unsoldering the rheofores and also
remove the solder from the bump contacts on the PCB;
- clean any irregularities or dirt from the dissipators. If the diodes
have burst the dissipator may be irreparably damaged: in such a
case it should be replaced;
- apply thermoconductive paste following the general
instructions;
- place the dissipator with the new components on the bump
contacts of the PCB and fasten it down with the screws (torque
wrench setting 1 Nm 20%);
- solder the terminals taking care not to let the solder run along
them;
- on the soldering side cut the protruding part of the rheofores
and make sure they have not shorted (between cathode and
anode).
N.B. make sure that resistor R1 and capacitor C1 of the snubber
are soldered correctly (fig. 3).
TESTING THE MACHINE
Tests should be carried out on the assembled machine before
closing it with the top cover. During tests with the machine in
operation never commute the selectors or activate the ohmic load
contactor.
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 machine to the static load generator (code
802110) using cables fitted with the appropriate dinse connectors.
B) Set up the dual trace oscilloscope with the voltage probe
CH1x100 connected between the collector (probe) and the emitter
of Q4 (earth) on the primary board (figure 3).
C) Pass the current probe of the Hall effect transducer along the
cable connecting the power transformer at faston CN10 with the
reference arrow pointing into CN10.
D) Lastly, connect the Hall Probe and the current probe to the
oscilloscope.
E) Set up a multimeter in DC volt mode and connect the prods to
the OUT+ and OUT- dinse connections.
F) On the front panel set switch SW1 to SOFT (as low as it will
go).
WARNING! the high frequency voltage will permanently damage
any instrument connected to the generator. Before proceeding
make very sure that the fastons listed above are disconnected and
completely isolated from one another.
TECHNOLOGY
TECHNOLOGY 150-170-200-186CE/GE
150-170-200-186CE/GE
G) Connect the power supply cable to the 230Vac power supply. C) Intermediate load test:
WARNING! during testing prevent contact with the metal part of - set up the ohmic load with the switch settings as in the table in
the torch because of the presence of high voltages that are fig. G;
hazardous to the operator. - on the front panel position the current potentiometer on approx.
80A;
1.2 Scheduled tests - start up the ohmic load and make sure that:
A) Loadless test: - the waveforms displayed on the oscillscope resemble
Switch on the machine, gradually increase the power supply those in Fig. G;
voltage from 0V to 230Vac and make sure that: - the output current is equal to +80Adc 10% and the output
- the pre-charge relays on the primary board close; voltage is equal to +23.2.Vdc 10%.
- the fan starts operating correctly; - switch off the ohmic load and switch off the main switch.
- the waveform displayed on the oscilloscope resembles Fig. E
and the frequency is equal to +32.5KHz 20%; G
FIGURE E
- the output voltage over dinse + and dinse is equal to 95Vdc
10%.
SETTINGS:
PROBE CH1 x100;
FIGURE E 100 V/Div;
PROBE CH4 =20A;
10mV/Div;
10 sec/Div.
SETTINGS:
PROBE CH1 x100;
VERIFY THAT
100 V/Div;
THE FREQUENCY IS
PROBE CH4 =1A;
60KHz 5%;
10mV/Div;
AMPLITUDE CH1 IS
105 sec/Div.
340V 10%;
AMPLITUDE CH4 IS
VERIFY THAT
26A 20%;
THE FREQUENCY IS
60KHz 5%;
AMPLITUDE CH1 IS
340V 10%;

1 2 3 4 5 6 Number switch
2 2 2 2 1 0 Position switch

A) Rated load test:

B) Rated load test:
- set up the ohmic load with the switch settings as in the table in
fig. G;
- on the front panel position the current potentiometer on
minimum (turn anti-clockwise as far as it will go);
- switch on the main switch;
- start up on the ohmic load and make sure that:
- the waveforms displayed on the oscilloscope resemble
those in Fig. F;
- the output current is equal to +5Adc20% and the output
voltage is equal to +20.2Vdc10%.
- switch off the ohmic load and switch off the main switch.
- the ohmic load with the switch settings according to the
relevant Technology model (see tables in Figs. H, I, J, K);
- on the front panel position the current potentiometer on
maximum (turn clockwise as far as it will go)
- start up on the ohmic load and make sure that:
For the Technology 150
- the waveforms displayed on the oscillscope resemble those in
Fig. H;
- the output current is equal to +130Adc 3% and the output
voltage is equal to +25.2Vdc 5%; if the output current reading
is not 130A 3%, adjust the current using trimmer IMAX R13
on the primary board (fig. 3).

FIGURE F
E H
FIGURE E

SETTINGS:
PROBE CH1 x100; SETTINGS:
100 V/Div; PROBE CH1 x100;
PROBE CH4 =5A; 100 V/Div;
10mV/Div; PROBE CH4 =20A;
10 sec/Div. 10mV/Div;
10 sec/Div.
VERIFY THAT
THE FREQUENCY IS VERIFY THAT
60KHz 5%; THE FREQUENCY IS
AMPLITUDE CH1 IS 32.5KHz 20%;
340V 10%; AMPLITUDE CH1 IS
AMPLITUDE CH4 IS 7A 340V 10%;
20%; AMPLITUDE CH4 IS
56A 10%;

1 2 3 4 5 6 Number switch 1 2 3 4 5 6 Number switch

1 0 0 0 0 0 Position switch 3 3 3 2 2 2 Position switch

- 15 -
 TECHNOLOGY 150-170-200-186CE/GE
For the Technology 170 K
FIGURE E
- the waveforms displayed on the oscillscope resemble those in
Fig. I;
- the output current is equal to +160Adc 3% and the output SETTINGS:
PROBE CH1 x100;
voltage is equal to +26.4Vdc 5%; if the output current reading 100 V/Div;
is not 160A 3%, adjust the current using trimmer IMAX R13 PROBE CH4 =20A;
10mV/Div;
on the primary board (fig. 3). 10 sec/Div.

I
FIGURE E VERIFY THAT
THE FREQUENCY IS
32.5KHz 20%;
AMPLITUDE CH1 IS
SETTINGS: 340V 10%;
PROBE CH1 x100; AMPLITUDE CH4 IS
100 V/Div; 58A 10%;
PROBE CH4 =20A;
10mV/Div;
10 sec/Div.

VERIFY THAT
THE FREQUENCY IS
32.5KHz 20%;
AMPLITUDE CH1 IS
340V 10%;
1 2 3 4 5 6 Number switch
AMPLITUDE CH4 IS 3 3 3 2 2 2 Position switch
60A 10%;

- switch off the ohmic load and switch off the main switch.

E) Checking the secondary diode voltages:

- set up the dual trace oscilloscope, connecting probe CH1 x
100 to the anode of diode D1 or D2 and probe CH2x100 to the
1 2 3 4 5 6 Number switch anode of diode D3 or D5. Earth connections are both made to
3 3 3 2 2 2 Position switch the secondary dissipator;
- remove the multimeter from the OUT+ and OUT- bump
contacts;
For the Technology 200 - set up the ohmic load with the switch settings according to the
- the waveforms displayed on the oscillscope resemble those in relevant Technology model (see tables at point 1.2D);
- on the front panel position the current potentiometer R7 to the
Fig. J;
maximum (turn the knob clockwise as far as it will go) and
- the output current is equal to +180Adc 3% and the output
switch on the main switch;
voltage is equal to +27.7Vdc 5%; if the output current reading - activate the static load generator and make sure that the
is not 180A 3%, adjust the current using trimmer IMAX R13 waveforms displayed on the oscilloscope resemble those in
on the primary board (fig. 3). fig. L;
- deactivate the static load generator and switch off the main
J
FIGURE E switch.

SETTINGS:
L
FIGURE E
PROBE CH1 x100;
100 V/Div;
PROBE CH4 =20A; SETTINGS:
10mV/Div; PROBE CH1 x100;
10 sec/Div. 50V/Div;
PROBE CH2 x100;
VERIFY THAT 50V/Div;
THE FREQUENCY IS 10 sec/Div.
32.5KHz 20%;
AMPLITUDE CH1 IS VERIFY THAT
340V 10%; REVERSE AMPLITUDE
AMPLITUDE CH4 IS ON CH1 DOES NOT
60A 10%; EXCEED 250V.
REVERSE AMPLITUDE
ON CH2 DOES NOT
EXCEED 250V.

1 2 3 4 5 6 Number switch
3 3 3 3 3 2 Position switch
1.3 Operational tests
A)Arc Force test
For the Technology 186CE/GE Set up the ohmic load as shown in the table in Fig. G and the
- the waveforms displayed on the oscillscope resemble those in current potentiometer on approx. 80A. Position switch SW1 on
Fig. K; HARD (in the centre), start the ohmic load and make sure the
- the output current is equal to +145Adc 3% and the output output current reading shows approx. 110A 10% then returns to
voltage is equal to +25.8Vdc 5%; if the output current reading the current setting
is not 145A 3%, adjust the current using trimmer IMAX R13 .
on the primary board (fig. 3). B)Running time test and closing the machine
On the front panel set switch SW1 to SOFT (as low as it will go and
the welding current to maximum). Under the relevant load
- 16 -
TECHNOLOGY
TECHNOLOGY 150-170-200-186CE/GE
150-170-200-186CE/GE
conditions for the particular Technology model (see tables at point C)Welding test
1.2 D), switch on the machine and leave it running until the MMA: with the machine set up according to the instructions in the
thermostatic capsules trigger (machine in alarm). After making handbook make a test weld with an electrode diam. 2.5 and the
sure the internal wiring is positioned correctly assemble the current setting at 80A. Monitor the dynamic behaviour of the power
machine once and for all. source, also checking for the presence of the Arc Force SW1 on
HARD (in the centre)
ILLUSTRATIONS
FIG. 1A
SCREWS
FASTENING SCREWS
BACK PANEL FASTENING
FRONT PANEL

SCRAWS
FASTENING
BACK PANEL

SCREWS
FASTENING
FRONT PANEL

FIG. 1B
TO
COVER SCREWS

TOP
COVER SCREWS

TOP
COVER SCREWS

- 17-
 TECHNOLOGY 150-170-200-186CE/GE
FIG. 2A
D9 SW1
YELLOW LED SWITCH
ALARM SELECTION
TIG/LIFT-HARD-SOFT

CURRENT
POTENTIOMETER

BOTTOM BOTTOM
COVER SCREWS COVER SCREWS

POSITIVE DINSE BOTTOM NEGATIVE DINSE

COVER SCREWS

FIG. 2B

GENERAL SWITCH
MAINS CABLE

FAN

BOTTOM BOTTOM
COVER SCREWS COVER SCREWS

- 18 -
TECHNOLOGY
TECHNOLOGY 150-170-200-186CE/GE
150-170-200-186CE/GE
FIG. 3

D4 D8 R6 Q4, Q3 CN10 D5, D3 C7, C2, C4, C6 JP1 U2 R40B Q10 SW1 R16

ISO2, ISO1 Q2, Q1 R2 CN3 R1 K2, K1 HYBRID BOARD R13 D32 U4 U6 D9

FIG. 4 D1, D2 R1, C1 SHUNT R1

D3, D5 ST1 THERMOSTAT

CABLE

- 19 -
 TECHNOLOGY 150-170-200-186CE/GE

ELENCO PEZZI DI RICAMBIO - LISTE PIECES DETACHEES

SPARE PARTS LIST - ERSATZTEILLISTE - PIEZAS DE REPUESTO
Esploso macchina, Dessin appareil, Machine drawing, Explosions Zeichnung des Gerts, Diseo seccionado maquina.

15 13

25 8

27 16

19 20

1 5 21 14 10 7 4 2 3 12 23 17

26 6 9 18 11 24 22
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.
Por pedir una pieza de repuesto sin referencia precisar: modelo-marca e tension de la maquina; numero di riferimento de lista; numero di matricula.

- 20 -
TECHNOLOGY
TECHNOLOGY 150-170-200-186CE/GE
150-170-200-186CE/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 Cavo Alim. Fondo
Potentiometre Cable Alim. Chassis
1 Potentiometer 10 Mains Cable 19 Bottom
Potentiometer Netzkabe Bodenteil
Potenciometro Cable Alim. Base
Resistenza Ventilatore Presa Dinse
Resistance Ventilateur Prise Dix
2 Resistor 11 Fan 20 Dinse Socket
Wiederstand Ventilator Dinse Steckdose
Resistencia Ventilador Enchufe Dinse
Rele' Trasformatore Di Corrente Ta Kit Diodi-igbt-resistenza
Relais Transformateur De Courant Ta Kit Diodes-igbt-resistance
3 Relais 12 Current Transformer Ta 21 Kit Diodes-igbt-resistance
Relais Stromwandler Ta Kit Diodes-igbt-wiederstand
Relais Transformador De Corriente Ta Kit Diodos-igbt-resistencia
Raddrizzatore Monofase Fibbia Kit Scheda Secondario
Redresseur Monophase Boucle Kit Fiche Secondaire
4 Single-phase Rectifier 13 Buckle 22 Kit Secondary Pcb
Einphasiger Gleichrichter Schnalle Kit Sekundaertrafokarte
Rectificador Monofasico Hebilla Kit Tarjeta Secundario
Condensatore Pressacavo Kit Scheda Primario
Condensateur Presse Cable Kit Fiche Primaire
5 Capacitor 14 Cable Bushing 23 Kit Primary Pcb
Kondensator Kabelhalter Kit Primrtrafokarte
Capacitor Prensa Cable Kit Tarjeta Primario
Condensatore Cinghia Kit Diodo
Condensateur Courroie Kit Diode
6 Capacitor 15 Belt 24 Kit Diode
Kondensator Gurt Kit Diode
Condensador Correa Kit Diodo
Interruttore Cornice Kit Manopola
Interrupteur Cadre Kit Poignee
7 Switch 16 Frame 25 Knob Kit
Schalter Rahmen Griff Kit
Interruptor Marco Kit Manija
Deviatore Frontale Kit Trasformatore + Induttanza
Gareur Partie Frontal Kit Tranformateur + Reactance
8 Switch 17 Front Panel 26 Kit Transformer + Reactance
Schalter Geraetefront Kit Trafo + Reaktanz
Interruptor Frontal Kit Transformador + Reactancia
Termostato Retro Kit Mantello
Thermostat Partie Arriere Kit Capot
9 Thermal Switch 18 Back Panel 27 Kit Cover
Thermostat Rueckseite Kit Deckel

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!

- 21 -
 TECHNOLOGY 150-170-200-186CE/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 circuit board: yes no
Rectifier bridge Substitution of primary control board: yes no
Electrolytic capacitors Troubles evinced during repair :
Relais
In-rush limiter resistance
IGBT
Snubber
Secondary diodes
Potentiometer
Others
- 22 -
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