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Telwin TECHNOLOGY TIG 172, Troubleshooting And Repair Manual

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Telwin TECHNOLOGY TIG 172 Troubleshooting And Repair Manual Download Page 1

cod. 988647

inverter

TECHNOLOGY TIG 172

AC/DC - HF/LIFT

TROUBLESHOOTING

AND REPAIR MANUAL

TROUBLESHOOTING

AND REPAIR MANUAL

“ r e p a r a t i o n n o p r o b l e m ! ”

TROUBLESHOOTING

AND REPAIR MANUAL

TROUBLESHOOTING

AND REPAIR MANUAL

CONTENTS

PAGE

OPERATION AND WIRING DIAGRAMS................ 2

REPAIR GUIDE.......................................................13

SPARE PARTS LIST...............................................26

REPAIR SHEET...................................................... 28

- Block diagram

2

- Analysis of the block diagram

3

- Illustrations

5

- Wiring diagrams

7

- Equipment required

13

- General repair instructions

14

- Troubleshooting and remedies

14

- Testing the machine

18

- Illustrations

21

Summary of Contents for TECHNOLOGY TIG 172

Page 1: ...SHOOTING AND REPAIR MANUAL TROUBLESHOOTING AND REPAIR MANUAL CONTENTS PAGE OPERATION AND WIRING DIAGRAMS 2 REPAIR GUIDE 13 SPARE PARTS LIST 26 REPAIR SHEET 28 Block diagram 2 Analysis of the block diagram 3 Illustrations 5 Wiring diagrams 7 Equipment required 13 General repair instructions 14 Troubleshooting and remedies 14 Testing the machine 18 Illustrations 21 ...

Page 2: ...OPERATION AND WIRING DIAGRAMS OPERATION AND WIRING DIAGRAMS OPERATION AND WIRING DIAGRAMS OPERATION AND WIRING DIAGRAMS HF TRANSFORMER SHUNT INDUCTANCE PRIMARY EMC FILTER POWER TRANSFORMER PRE CHARGE RECTIFIER BRIDGE FILTER CHOPPER SECONDARY DIODES SECONDARY EMC FILTER CURRENT TRANSFORMER FAN POWER SUPPLY LED PRIMARY CURRENT READER MICROCONTROLLER UNDERVOLTAGE SAFEGUARD DUTY CYCLE MAKER ADDER TORC...

Page 3: ...direction preventing saturation of the nucleus D6 D7 D8 recirculate the inductance output current block 9 during the time when the IGBT s are not conducting bypassing the power transformer block 7 The positive polarity diodes in the circuit are involved The positive and negative polarity diodes in the circuit are involved alternately Consisting of SCR secondary board The SCR module is piloted by b...

Page 4: ... Microcontroller Galvanic separation Inductance thermostat Secondary diode thermostat Control panel Shunt Amplifier Consisting of U13A U13B control board Collects the information from block 26 maximum current regulator and block 18 microcontroller producing a voltage signal that is suitable for processing by block 16 duty cycle maker Consisting of U4 control board Control logic which manages typic...

Page 5: ...R SHUNT 3 PRE CHARGE 16 DUTY CYCLE MAKER 5 Primary board TECHNOLOGY TIG 172 AC DC Control board 19 20 UNDERVOLTAGE OVERVOLTAGE SAFEGUARD 2 RECTIFIER BRIDGE 13 FLY BACK TRASFORMER 4 FILTER 1 EMC FILTER 21 GALVANIC SEPARATION 6 CURRENT TRASFORMER ILLUSTRATIONS 15 PRIMARY CURRENT READER AND LIMITER ...

Page 6: ...ECONDARY DIODES 9 AC DC CURRENT CONVERTER 30 SOLENOID VALVE RELAY 29 AUXILIARY TRASFORMER 6 Secondary board Torch button board 27 SCR DRIVER 10 SHUNT TECHNOLOGY TIG 172 AC DC 32 SOLENOID VALVE RELAY AND HF ...

Page 7: ... 7 TECHNOLOGY TIG 172 AC DC WIRING DIAGRAMS General wiring diagram ...

Page 8: ... 8 TECHNOLOGY TIG 172 AC DC Wiring diagram primary board Power Wiring diagram primary board Driver ...

Page 9: ... 9 TECHNOLOGY TIG 172 AC DC Wiring diagram control board Micro Wiring diagram primary board power supply ...

Page 10: ... 10 TECHNOLOGY TIG 172 AC DC Wiring diagram control board Digital Wiring diagram control board Analogyc ...

Page 11: ... 11 TECHNOLOGY TIG 172 AC DC Wiring diagram control board In Out Wiring diagram secondary board Power ...

Page 12: ... 12 Wiring diagram HF board Wiring diagram PT board TECHNOLOGY TIG 172 AC DC Wiring diagram secondary board Driver ...

Page 13: ... REPAIR GUIDE REPAIR GUIDE REPAIR GUIDE EQUIPMENT REQUIRED ESSENTIAL INSTRUMENTS USEFUL INSTRUMENTS 1 Dual trace oscilloscope cod 802401 2 Static load generator cod 802110 3 Variac 0 300v 1500 VA cod 802402 4 Digital multimeter 6 Unsoldering station 7 Miscellaneous tools 5 Differential probe 1 200 6 Hall Probe cod 802406 cod 802403 7 HV Power supply ...

Page 14: ...0 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 o...

Page 15: ...rews connecting the shunt to the PCB Check the solenoid valve to see if it opens Probable causes the solenoid valve does not open because of a mechanical block do not attempt to open the valve but used compressed air to carry out thorough cleaning or replace the solenoid valve Maintenance status referring to the instructions given in the instruction manual Condition of parts not subject to wear on...

Page 16: ...y H Set up the oscilloscope with the voltage probe x10 connected between the gate probe and the emitter earth of IGBT Q4 on the primary board I Switch on the HV power supply HV out and make sure the waveform displayed on the oscilloscope resembles fig 7 fig 7 A B Fig B N B fig 5 fig 5 fig C N B fig 7 fig 5 fig D 6 0 Electrical measurements with the machine in operation WARNING fig 3 fig 4 fig 5 WA...

Page 17: ...uired by the procedure never alter the board trimmers If the fault is in the control board remove it from the primary board as follows with the machine disconnected from the main power supply disconnect all the wiring from the control board cut any bands restricting the board remove the control board from the spacers attached to the primary board for assembly proceed in the reverse order If the fa...

Page 18: ...nubber are soldered correctly to the bottom board The SCR module is attached to the dissipator and to reach it it is necessary to remove the top board undo the 3 screws fastening the SCR module to the top board disconnect the 4 fastons connected to the SCR module remove the top board remove the SCR module by undoing the 2 screws at the side clean any irregularities or dirt from the dissipators If ...

Page 19: ...ch off the ohmic load and switch off the main switch on the front panel set switch SW2 to TIG 2T as high as it will go and switch SW3 to AC as low as it will go connect the TIG torch to the machine set up the dual trace oscilloscope connecting probe CH1 x10 to pin 1 of connector J3 on the control board and probe CH2 x 10 to pin 2 The earths are connected together to pin 3 on the same J3 connector ...

Page 20: ...peration until the thermostatic capsules trigger machine in alarm After making sure the internal wiring is positioned correctly re assemble the machine once and for all with the machine set up according to the instructions in the handbook make a test weld with an electrode diam 2 5 and the current setting at 80A Monitor the dynamic behaviour of the power source also checking for the presence of th...

Page 21: ...1B ILLUSTRATIONS SCRAW FASTENING FRONT PANEL TOP COVER SCRAWS TOP COVER SCRAWS TOP COVER SCRAWS BOTTOM COVER SCRAWS TECHNOLOGY TIG 172 AC DC SCRAW FASTENING BACK PANEL SCRAW FASTENING FRONT PANEL BOTTOM COVER SCRAWS ...

Page 22: ...ATIONS ENCODER ALPHANUMERIC DISPLAY SWITCH SW2 2T 4T MMA SELECTION BOTTOM COVER SCREWS BOTTOM COVER SCREWS MAINS CABLE GENERAL SWITCH FAN REMOTE CONNECTOR GA STUBE CONNECTOR PRIMARY BOARD FASTON CN3 FASTON CN10 CONTROL BOARD PANEL BOARD PRIMARY BOARD FASTENING SCREWS SOLENOID VALVE FASTENING SCREWS TRANSFORMATOR INDUCTANCE KIT FASTENING SCREWS PRIMARY BOARD FASTENING SCREWS SECONDARY BOARD TRASFOR...

Page 23: ...4 D8 R6 Q4 Q3 D5 D3 C7 C2 C4 C6 JP1 R40A Q10 TORCH BUTTON BOARD FUSE F1 RELAIS K1 DIODES RECTIFIER D1 BOARDHF TRANSFORMATOR HF FASTON J1 E J3 ON HF BOARD SCR Q1 SUPPORT BOARD ISO2 ISO1 PRIMARY DISSIPATOR Q2 Q1 R2 R1 K2 K1 J6 J4 U2 U5 D32 U4 U6 ...

Page 24: ...FIG 6 24 ISO1 ISO3 ISO2 ISO4 R1 R2 R3 R4 FAN TECHNOLOGY TIG 172 AC DC METALLIC STRUCTURE SHUNT R2 ST1 THERMOSTAT CABLE RELAIS K2 SECONDARY DIODES J3 J7 R105 IMAX J11 J10 J1 J14 J13 J15 J16 R162 FREQ J12 J9 J5 ...

Page 25: ... BI LEVEL EV ON EV ON HF OFF HF OFF EV ON EV ON HF OFF HF OFF EV ON EV ON HF OFF HF OFF EV ON EV ON HF OFF HF OFF EV ON EV ON HF OFF HF OFF EV OFF EV OFF HF OFF HF OFF EV OFF EV OFF HF OFF HF OFF EV ON EV ON HF ON HF ON Welding current LEVEL 1 P T ON P T ON P T ON P T ON P T OFF P T OFF P T OFF P T OFF Welding current LEVEL 2 LEGENDA EV Solenoid valve HF High Frequency if active I Welding current ...

Page 26: ...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 nume...

Page 27: ...qua Raccord Eau Pipe Fitting Wasseranschluss Racor Agua Retro Partie Arriere Back Panel Rueckseite Trasera Frontale Partie Frontal Front Panel Geraetefront Frontal Fondo Chassis Bottom Bodenteil Fondo Fondo Chassis Bottom Bodenteil Fondo Presa Dinse Prise Dix Dinse Socket Dinse Steckdose Enchufe Dinse Kit Raccordo Entrata Gas Kit Raccord Entree Gaz Gas Pipe Connector Kit Gaseintrittkit Kit Racor E...

Page 28: ...thout extension From mains with extension m Mechanichal stresses the machine has undergone to cription Des Dirty grade Dirty inside the machine Description Rectifier bridge Electrolytic capacitors Relais In rush limiter resistance IGBT Snubber Secondary diodes Potentiometer Others Kind of failure Component ref Substitution of primary circuit board yes no Substitution of primary control board yes n...

Page 29: ...WIN 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 CERTIFIED QUALITY SYSTEM UNI EN ISO 9001 2000 ISO 9001 ...

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