cod.

988401

TECNICA 1400-1600
TECNICA 140.1 - 142
inver ter

TROUBLESHOOTING
AND REPAIR MANUAL

CONTENTS PAGE

OPERATION AND ELECTRICAL DIAGRAMS................... 2

- Block diagram 2
- Analysis of block diagram 3
- Illustrations 5
- Electrical diagrams 6

REPAIR GUIDE.................................................................. 10
- Equipment required 10
- General repair instructions 11
- Troubleshooting and remedies 11
- Testing the machine 14
- Illustrations 16

SPARE PARTS LIST.......................................................... 17

REPAIR SHEET................................................................. 19

31/05/02

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

1 2 3 4 5 6 7 8 9 10 11

BLOCK DIAGRAM

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FAN POWER DRIVER CURRENT READER ALARM LED MAX CURRENT
FLY-BACK
SUPPLY LED ADJUSTMENT
POWER SUPPLY

26 25 12 13 14 19 20

-2-
DUTY CYCLE ADDER ALARM BLOCK POTENTIOMETER
MAKER

UNDERVOLTAGE
SAFEGUARD 15 16 17 18

CONTROLLO
24
TECNICA 1400 - 1600

POWER GALVANIC OVERVOLTAGE

TRANSFORMER SEPARATOR AFEGUARD
THERMOSTAT

21 22 23
OPERATION AND WIRING DIAGRAMS
 TECNICA 1400 - 1600
ANALYSIS OF THE BLOCK DIAGRAM Block 8
Power transformer
NOTE: Unless indicated otherwise, it should be Consisting of: T3
assumed that the components are assembled on the Reduces the voltage converted by block 6 (chopper),
primary board. adjusting voltage and current to values required for
Block 1 the welding procedure.
EMC Filter Also forms galvanic separation of primary from
Consisting of: C1, C5, C6, L1 secondary (welding circuit from the power supply
Prevents noise from the machine from being line).
transmitted along the main power line and vice versa.
Block 9
Block 2 Secondary diodes
Varistor Consisting of: D21, D22, D23
Consisting of: RV1 D21 Eliminates the negative part of the secondary
Prevents spike noise from the mains, with amplitude voltage.
greater than 400V, from entering the machine. D22,D23 Recirculate the inductance output current
when the IGBT’s are not conducting.
Block 3
Pre-charge Block 10
Consisting of: K1, R1 Reactance
Prevents the formation of high transitory currents that Consisting of: L2
could damage the main power switch, the rectifier Levels the secondary board diodes’ output current
bridge and the electrolytic capacitors. making it practically continuous.
When the power source is switched on the relay K1 is
de-energised, capacitors C2, C3, C4 are then Block 11
charged by R1. When the capacitors are charged the Secondary EMC Filter
relay is energised. Consisting of: C31, C32
Prevents noise from the power source from being
Block 4 transmitted through the welding cables and vice
Rectifier bridge versa.
Consisting of: D1 Block 12
Converts the mains alternating voltage into Flyback power supply
continuous pulsed voltage. Consisting of: T1, U2, U1
Uses switching methods to transform and stabilise
Block 5 the voltage obtained from block 5 (filter) and supply 2
Filter voltage values of 27V that enable block 13 (driver) to
Consisting of: C2, C3, C4 be powered correctly. It also generates a further
Converts the pulsed voltage from the rectifier bridge stabilized voltage of 15V that is mainly used to power
into continuous voltage. the control board.

Block 6 Block 13
Chopper Driver
Consisting of: Q1, Q2 Consisting of: ISO2, ISO3
Converts the continuous voltage from the filter into a Takes the signal from block 12 (flyback power supply)
high frequency square wave (65 kHz approx.) and, controlled by block 15 (duty cycle maker),
capable of piloting the power transformer. makes the signal suitable for piloting block 6
Regulates the power according to the required (chopper).
welding current/voltage.
Block 14
Block 7 Primary current reader
Current transformer Consisting of: R20, R37, R38 and part of the control
Consisting of: T2 section.
The C.T. is used to measure the current circulating in Reads the signal from block 7 (current transformer)
the power transformer primary and transmit the and scales it down so it can be processed and
information to block 14 (primary current reader). compared in blocks 15 and 16.
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 TECNICA 1400 - 1600

Block 15 Block 21
Duty cycle maker Power transformer thermostat
Consisting of: U2 (control board) = UC 3845 Consisting of: ST1 thermostatic capsule.
Processes the information from block 16 (adder) and When the temperature of the power transformer is
block 14 (primary current reader) and produces a too high, this safeguard is triggered. It is reset
square wave with variable duty cycle limiting the automatically after the alarm condition has ceased.
primary current to a maximum pre-set value under all
circumstances.
Block 22
Block 16 Galvanic separator
Adder Consisting of: ISO1
Consisting of: U1D (control board) The signal from the thermostatic capsules is
Gathers all the information from block 14 (primary separated galvanically and sent to block 17 (alarms)
current reader), from block 17 (alarms) and from for identification of possible alarm condition.
block 18 (potentiometer), and produces a signal with
a suitable voltage for processing by block 15 (duty Block 23
cycle maker). Overvoltage safeguard
Consisting of: R3, R4 and part of the control section
Block 17 If the main supply voltage exceeds the maximum
Alarm Block value this safeguard triggers (a tolerance of approx.
Consisting of: U1A, U1C (control board) ±15% of the power supply voltage is allowed: outside
When an alarm is detected the machine output this range the safeguard triggers).
current is drastically reduced by directly adjusting
and changing the reference signal obtained from Block 24
block 18 (potentiometer). Undervoltage safeguard
Consisting of: R5, R6 and part of control board
Block 18 If the main supply voltage falls below the minimum
Potentiometer allowed value this safeguard triggers (a tolerance of
Consisting of: R7 approx. ±15% of the power supply voltage is allowed:
This is used to create the reference voltage needed to outside this range the safeguard triggers).
adjust the output current: when the potentiometer is
turned the cursor voltage varies, thus varying the Block 25
current from the minimum to the maximum value. Power supply LED
Consisting of: D2
Block 19 Shows that the machine is correctly powered and
Yellow LED alarm light ready to weld.
Consisting of: D26 (yellow) On machines operating exclusively at 230V it is
It is switched on by block 17 (alarms) in the event of: green.
1) Triggering of thermostatic capsule on power
transformer. Block 26
2) Triggering due to undervoltage. Fan
3) Triggering due to overvoltage. Cools the power components. On machines
4) Short circuit at output (electrode holder and earth operating exclusively at 230V it is powered directly by
cable connected to each other or electrode stuck block 12 (at 12V).
to piece being welded).

Block 20
Maximum current adjustment
Consisting of: R32, R33, R42
Used to adjust the maximum welding current
supplied by the power source.

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 TECNICA 1400 - 1600
ILLUSTRATIONS
Power board

4
3 PRE-CHARGE
1 RECTIFIER BRIDGE 8
12 POWER TRANSFORMER
EMC FILTER FLY-BACK
TRANSFORMER 18
POTENTIOMETER

25
POWER
SUPPLY LED
19
ALARM LED
15 DUTY CYCLE
MAKER
5
FILTER 22
GALVANIC
SEPARATOR

10
INDUCTANCE

21
THERMOSTATIC
9 CAPSULE
6 13 SECONDARY
DRIVER ON POWER
CHOPPER DIODES
11 TRANSFORMER
SECONDARY
EMC FILTER

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 TECNICA 1400 - 1600
WIRING DIAGRAM

General wiring diagram – TECNICA 1400 – 1600

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 TECNICA 1400 - 1600

Wiring diagram for power – power supply/control board

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 TECNICA 1400 - 1600

Wiring diagram for power – power/driver board

IGBT

IGBT

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 TECNICA 1400 - 1600

Wiring diagram for control board

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 TECNICA 1400 - 1600

REPAIR GUIDE
EQUIPMENT REQUIRED

4 1 3 2 5

6 7

ESSENTIAL INSTRUMENTS
1 Dual trace oscilloscope cod. 802401 (*)
2 Static load generator cod. 802110 (*)
3 Variac 0 - 300v 1500 VA cod. 802402 (*)
4 Digital multimeter

USEFUL INSTRUMENTS
5 Unsoldering station

MISCELLANEOUS
6 Cutting nippers
7 Flat jaw pincers

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

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 TECNICA 1400 - 1600
GENERAL REPAIR INSTRUCTIONS 2) Cleaning the inside of the machine
Using compressed air, carefully clean the components of
The following is a list of practical rules which must be the power source since dirt is a danger to parts subject to
strictly adhered to if repairs are to be carried out correctly. high voltages and can damage the galvanic separation
A) When handling the active electronic components, the between the primary and secondary.
IGBT’s and Power DIODES in particular, take It is therefore important to take special care when cleaning
elementary antistatic precautions (use antistatic the following parts
footwear or wrist straps, antistatic working surfaces
etc.).To ensure the heat flow between the electronic Fan (figure 2A): check whether dirt has damaged the
components and the dissipator, place a thin layer of correct rotation of the blades, if there is still damage after
thermo-conductive grease (e.g. COMPOUND cleaning replace the fan.
GREASIL MS12) between the contact zones.
The power resistors (should they require replacement) Power board (figure 2A e 2B):
should always be soldered at least 3 mm above the A) Rheofores of IGBT’s Q1, Q2,
board. B) Rheofores of recirculating diodes D14, D20,
D) If silicone is removed from some points on the boards, it C) Rheofores of secondary power diodes D21,D22,D23,
should be re-applied. D) Thermostatic capsule on power transformer (figure 3),
NB. Use only non-conducting neutral or oximic reticulating E) Photocoupler ISO1 (figure 3),
silicones (e.g. DOW CORNING 7093). Otherwise, F) Control board (figure 3).
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. 3) Visual examination of the machine
E) When the semi-conductor devices are soldered the Make sure there is no mechanical deformation, dent, or
maximum temperature limits should be respected damaged and/or disconnected connector.
(normally 300°C for no more than 10 seconds). Make sure the power supply cable has not been damaged
F) It is essential to take the greatest care at each or disconnected internally and that the fan works with the
disassembly and assembly stage for the various machine switched on.
machine parts. Make a visual check of components listed below for signs
G) Take care to keep the small parts and other pieces that of burning or breakage:
are dismantled from the machine so as to be able to
position them in the reverse order when re-assembling A) Main power supply switch (figure 2A)
(damaged parts should never be omitted but should be Use the multimeter to check whether the contacts are
replaced, referring to the spare parts list given at the stuck together or open.
end of this manual). Probable cause: Mechanical or electric shock (e.g.
H) The boards (repaired when necessary) and the wiring bridge rectifier or IGBT in short circuit, handling under
should never be modified without prior authorisation load).
from Telwin. B) Current potentiometer R7 (figure 3)
I) For further information on machine specifications and Probable cause: mechanical shock.
operation, refer to the Instruction Manual. C) Varistor RV1 (figure 3)
J) WARNING! When the machine is in operation there Probable cause: machine connected to power supply
are dangerously high voltages on its internal parts so voltage much higher than 230Vac (e.g.380 Vac).
do not touch the boards when the machine is live. D) Relay K1 (figure 3)
Probable cause: see main power supply switch
NB. If the relay contacts are stuck together, do not attempt
to separate them and clean them, just replace the
TROUBLESHOOTING AND relay.
REMEDIES E) Electrolytic capacitors C2,C3 (figure 3)
Probable cause:
- mechanical shock,
1) Disassembling the machine - machine connected to power supply voltage much
Every operation should be carried out in complete safety higher than 230Vac,
with the power supply cable disconnected from the mains - broken rheophore on one or more capacitor: the
outlet. remainder will be overstressed and become damaged
A) Undo the 10 screws fastening the cover to the bottom:5 by overheating,
screws on each side (figure 1). - aging after a considerable number of working hours,
B) Slide out the cover upwards (figure 1). - overheating caused by thermostatic capsule failure.
F) IGBT’s Q1, Q2 (figure 4)
After completing the repairs, proceed in the reverse order Probable cause:
to re-assemble the cover and do not forget to insert the - discontinuation in snubber network,
toothed washer on the ground screw. - fault in driver circuit

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 TECNICA 1400 - 1600
- poorly functioning thermal contact between IGBT and transformer: clean the paint from the bump contacts of
dissipator (e.g. loosened attachment screws:check), J4 and measure the resistance between the two bump
- excessive overheating related to faulty operation. contacts, it should be approx. 0 ohm (figure 2B).
G) Primary diodes D14, D20 (figure 4)
Probable cause: excessive overheating related to faulty
operation..
6) Electrical measurements with the
H) Secondary diodes D21, D22, D23 (figure 4) board machine in operation
removed from the machine) The tests described below can be used to check the
Probable cause: operation of the power and control parts of the machine
- discontinuation in snubber network,
- poorly functioning thermal contact between IGBT and Preparation for testing.
dissipator (e.g. loosened attachment screws:check), A) Set up the oscilloscope with voltage probe x100
- faulty output connection connected between pin 3 of U2 (probe) and the case of
I) Power transformer and filter reactance (figure 2A). U1 (ground) on the power board (figure 3).
B) Position the potentiometer R7 on maximum (turn
clockwise as far as it will go).
4) Checking power and signal wiring C) Connect the machine plug to a single-phase variac with
It is important to check that all the connections are in good variable output 0-300 Vac.
condition and the connectors are inserted and/or attached
correctly. Tests for theTECNICA 1400
To do this, take the cables between finger and thumb (as
A) Switch on the variac (initially set to the value 0 V), switch
close as possible to the fastons or connectors) and pull
off the main switch on the machine, increase the variac
outwards gently: the cables should not come away from
voltage gradually to 230 Vac and make sure:
the fastons or connectors.
- the pre-charge relay K1 commutes (figure 3),
In particular, on the power board (figure 2A) it is
- the green power supply LED D2 lights up (figure 3),
necessary to check the power wiring:
- the fan starts up correctly,for voltages close to the rated
A) The connection of the power supply cable to the
power supply value (230Vac ±15%) the machine is not
fastons at the main switch and to the faston on the earth
in alarm status (yellow LED D26 off). NB. If the machine
board (J3),
stays in alarm status permanently, there could be a fault
B) The connections from the board to the main switch (J1,
in the control board (in any case, proceed to make the
J2),
other tests as in figure 3)
In particular, on the power board (figure 2B) it is
B) Use the oscilloscope to make sure that the voltage
necessary to check the signal wiring :
waveform between pin 3 of U2 and the ground
A) The connections of the thermostatic capsule on the
resembles that in figure A.
power transformer (J4),
B) The fan connections (J5+, J5-), FIGURE A
Other checks:
Make sure the connectors to the dinse sockets are
attached correctly (figure 2B)

5) Electrical measurements with the

machine switched off
With the digital multimeter set for diode testing check the
following components (junction voltages not less than
0.2V):
A) Rectifier bridge D1 (figure 3).
B) IGBT’s Q1, Q2 (absence of short circuits between
collector-gate and between emitter-collector figure 4).
C) Secondary board diodes D21, D22, D23 between
anode and cathode (figure 4).
NB. This can be done without removing the board: with one
prod on the secondary board dissipator diodes and the Amplitude tolerance: ±10%
other in sequence on the two power transformer outlets. Frequency: 65KHz ± 10%

With the digital multimeter set on ohms check the following

NB. If no signal is present, it may be necessary to replace
components:
the integrated circuit U2 (figure 3).
A) Resistor R1: 47ohm 7W ±5% (pre-charge figure 3).
B) Resistors R21,R27: 22ohm 13W ±5% (primary
C) With the digital multimeter set on volts place the
snubber figure 3).
negative prod on the ground of U1 and check the following
C) Resistor R31: 10ohm 5W ±5% (secondary snubber
points with the positive prod:
figure 3).
- make sure that the voltage between pin 1 of U1 and the
D) Thermostatic capsule continuity test on the power
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 TECNICA 1400 - 1600
ground is equal to +18V ±1V (figure 3). Switch off the machine and disconnect the oscilloscope.
- make sure that the voltage between pin 3 of U1 and
the ground is equal to +15V ±0.5V (figure 3). F) Switch the machine on again at 230Vac and make sure
- make sure that the voltage between pin 2 of U2 and that, following the brief start up time, the machine is not
the ground is equal to +13V ±1V (figure 3). in alarm status (the yellow alarm LED D26 is off, figure
- make sure that the voltage between pad J5 and the 3).
ground is equal to +13V ±1V (figure 3).
N.B. If the machine remains in alarm status (and this is not
D) Set up the oscilloscope with the probe x100 connected due to a fault in the control board) there could be a fault in
between the collector (probe) and emitter (ground) of the photocoupler ISO1 (figure 3).
IGBT Q1.
Make sure the displayed waveform resembles that in Tests for theTECNICA 1600:
figure B. In this case the tests are just the same and can be carried
FIGURE B
out in the same way.

7) 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). 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.

REMOVINGTHE POWER BOARD (figure 2A)

Amplitude tolerance: ±10% - With the machine disconnected from the main supply,
Frequency: 65KHz ± 10%
disconnect all the wiring connected to the board.
- Remove the current adjustment knob on the front panel
N.B. If this signal is not present, there may be a fault in
of the machine ( figure 1).
the IGBT driver circuit (figure 4) or the control board
- Remove any bands constraining the board (e.g. on the
(figure 3). In the latter case, we recommend replacing
power supply cable and connections to primary).
the board.
- Use a screwdriver from the welding side to undo the two
screws fastening the dinse sockets to the printed circuit
E) Set up the oscilloscope with the probe x10 connected
board (figure 2B).
between pin 9 of the strip J6 (probe) and the case of U1
- Use a screwdriver to undo the 4 screws fastening board
(ground) (figure 3). Make sure the displayed waveform
to the bottom (2 screws on the component side of the
resembles that in figure C. Make sure the output
board and 2 on the bottom of the machine figure 2B).
voltage between OUT+ and OUT- is equal to 85V ±10V.
- After removing the screws, lift the board upwards to
FIGURE C remove it from the bottom of the machine.
NB. To re-assemble, proceed in the reverse order,
remembering to insert the toothed washers on the
ground screws.

A) Please read the procedure for replacing the IGBT’s

carefully: (figure 4).
The 2 IGBT’s are attached to 2 different dissipators and
whenever a replacement is required, both IGBT’s should
be replaced.
- Undo the screws attaching the dissipator to the board to
replace Q1.(figure 2B)
- Undo the screws attaching the dissipator to the board to
replace Q2 (figure 2B)
- Remove the 2 IGBT’s Q1,Q2 and the 2 diodes D20, D14
by unsoldering the rheofores and then clean the solder
from the printed circuit bump contacts.
- Remove the 2 dissipators from the board.
Peak amplitude 0.5V ± 20%
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 TECNICA 1400 - 1600
- Remove the springs locking the 2 IGBT’s. cathode and anode).
- Before making the replacement make sure the NB. Make sure resistor (R31) and capacitor (C30) on the
components piloting the IGBT’s are not also damaged: snubber have been soldered to the PCB correctly (figure
With the multimeter set on ohms make sure there is no 3).
short circuit on the PCB between the 1st and 3rd bump
contacts (between gate and emitter) corresponding to C) Control board (figure 3)
each component Whatever fault occurs in the control board, we strongly
.- Alternatively, resistors R22 and R29 could have burst recommend its replacement without attempts at repair.
and/or diodes D12, D15, D17 and D19 may be unable to To remove it, cut and then unsolder the connector keeping
function at the correct Zener voltage (this should have it fixed perpendicular to the power board, replace it and
shown up in the preliminary tests). resolder the connector.
- 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
TESTING THE MACHINE
replaced. The test should be carried out on the assembled machine
- Apply thermoconductive grease following the general before closing it with the cover.
instructions. During tests with the machine in operation never commute
- Insert the new IGBT’s between the dissipator and the the selectors or activate the noninductive load
spring, taking care not to damage the component electromagnetic switch.
during assembly (the spring should be inserted under Preparation for testing.
pressure on the dissipator so as to lock the component). A) Connect the machine to the static load generator (code
- Place the dissipators with the new IGBT’s and primary 802110) using cables supplied with the appropriate
diodes D14 and D20 (WARNING! Make sure there is dinse connectors.
insulation between the case of diode D20 and the B) Set up the oscilloscope with 2 channels.
dissipator) in the PCB bump contacts, placing 4 C) Connect the voltage probe (CH1) x 100 between the
spacers between the dissipator and the PCB (2 for each collector (probe) and emitter (ground) of IGBT Q1.
dissipator) and fasten them down with the screws D) Connect the voltage probe (CH2) x 10 between PIN 9 of
(torque wrench setting for screws 1 Nm ±20%). strip J6 (probe) and the emitter.
- Solder the terminals taking care not to let the solder run E) Connect the machine plug to the variac.
along them.
- On the welding side cut away the protruding part of the Tests for theTECNICA 1400.
rheofores and check they are not shorted (between the A) Average load test:
gate and emitter in particular) . - With the static load generator disconnected, switch on
the variac and the machine main switch.Gradually take
B) Please read the procedure for replacing the secondary the power supply voltage from 0V to 230Vac, make sure
board diodes carefully: (figure 4). the pre-load relay commutes, the fan starts operating
The 3 SECONDARY DIODES are attached to the same correctly and the power supply LED D2 lights up.
dissipator, and when a replacement is required, all three Set up the static load generator with the switch settings
should be replaced: as in the table in figure D, on the front panel position the
- Undo the screws attaching the dissipator to the board, welding current potentiometer on 60A and switch on the
to replace D21, D22 and D23. power supply:
- Remove the 3 secondary diodes D21, D22 and D23, - Check that the voltage waveforms on the oscilloscope
unsoldering the rheofores and cleaning any solder from display resemble those in figure D.
the bump contacts on the board.
- Remove the dissipator from the board. FIGURE D
- Remove the spring locking the 3 diodes.
- Clean any irregularity or dirt from the dissipator. If the
diodes have burst the dissipator may have been
irreversibly damaged: in this case it should be replaced.
- Apply thermoconductive grease following the general
instructions.
- Insert the new diodes between the dissipator and the
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).
- Place the dissipator with the new components in the
PCB bump contacts and fasten them down with the
screws (torque wrench setting for screws 1 Nm ±20%).
- Solder the terminals taking care not to let the solder run Voltage at ends of load: 20.5V ±5%
along them. Current in load: 60A ±3%
- On the welding side cut away the protruding part of the SWITCH NUMBER
rheofores and check they are not shorted (between 0 SWITCH POSITION

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 TECNICA 1400 - 1600
B) Rated load test:Set up the static load generator with the D) Running time check and closing the machine:
switch settings as in the table in figure E, on the front - With the load status as in figure E and the current
panel turn the welding current potentiometer clockwise adjustment potentiometer on maximum, switch on the
to maximum and switch on the power supply. machine and leave it in operation until the thermostatic
- Check that the voltage and current waveforms on the capsules trigger (machine in alarm status).
oscilloscope display resemble those in figure E. - Check the correct positioning of the internal wiring and
finally re-assemble the machine.
FIGURE E E) Welding test:
With the machine preset as given in the instruction
manual make a test weld with a current of 80A
(electrode diam. 2.5 mm): check the dynamic behaviour
of the machine.

Tests for theTECNICA 1600:

The tests for the Tecnica 1600 are as above and can be
carried out in the same way except for the rated load test
(see B) and the voltage check on the secondary diodes
(see C).
NB. Rated load:
- Set up the static load generator with the switch settings
as in the table in table 1, on the front panel turn the
welding current potentiometer clockwise as far as it will
go (maximum) and switch on the power supply.
CH1 maximum amplitude 320V ± 10% - Check that the voltage and current waveforms on the
CH2 peak amplitude 8V ± 10%
oscilloscope display resemble those in figure E.Make
SWITCH NUMBER sure the current value on the static load generator is
SWITCH POSITION
149A±3% with a voltage of 26V± 5%.NB. Checking the
Voltage at ends of load: 24.8V ±5% secondary board diode voltages:
Current in load: 120A ±3% - Set up the static load generator with the switch settings
as in table 1, on the front panel turn the welding current
C) Checking the secondary diode voltages: potentiometer clockwise to maximum and switch on the
- Connect 2 voltage probes x100 between the 2 outlets of power supply.
the power transformer T1 (probe) and the secondary - Check that the voltage waveforms on the oscilloscope
dissipator (ground). display resemble those in figure F.
- Connect the 2 probes to the oscilloscope and under the
load conditions given in the second table in figure E SWITCH NUMBER
switch on the machine and position the current SWITCH POSITION
adjustment potentiometer on maximum (turn clockwise
as far as it will go). Table 1
- Check that the voltage waveforms on the oscilloscope
display resemble those in figure F. WARNING!
Voltage and current measurements for the TECNICA 1400
FIGURE F and 1600 should be made at a main power supply voltage
of at least 220Vac.
Main supply voltage should be measured over the main
power switch with the machine operating at full power.

Amplitude tolerance: ±10%

Reverse voltage peak should not exceed 150V

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 TECNICA 1400 - 1600
ILLUSTRATIONS
FIG. 1

CURRENT
ADJUSTMENT
COVER POTENTIOMETER
FASTENING
SCREWS POWER
SUPPLY LED

ALARM LED

COVER DINSE SOCKETS

FASTENING SCREWS

FIG. 2A MAIN
FIG. 2B BOARD
SWITCH FAN BUMP
BOARD FASTENING
CONNECTIONS FAN WIRES FILTER CONTACTS RHEOFORES RHEOFORES
FASTENING SCREW (J5+, J5-) SCREW
REACTANCE Q2 14
MAIN
SUPPLY SWITCH POWER BOARD
FILTER
CAPACITORS

FASTENING
SCREWS
FOR DINSE
SOCKET
CONNECTORS IGBT Q2
DISSIPATOR
FASTENING
SCREWS

IGBT Q1
DISSIPATOR
FASTENING
SCREWS
RHEOFORES THERMOSTATIC
SECONDARY CAPSULE
D23, D22, D21
DISSIPATOR
BUMP BOARD
SECONDARY CONTACTS
FASTENING BOARD J4 ATTACHMENT
SECONDARY DISSIPATOR SCREW
IGBT POWER SCREW ATTACHMENT RHEOFORES
FAN DIODES FASTENING
DISSIPATORS BOTTOM TRANSFORMER SCREW SCREW Q1 RHEOFORES D20

FIG. 3 FIG. 4
FLY-BACK TRANSFORMER
DIODE BRIDGE D1
CONTROL BOARD IGBT Q2
C3 RV1 R1 RELÈ K1 U1 IGBT DRIVER
U2
R7
DIODE BRIDGE
D14

LED
D2

C2 LED
D26
R21
ISO 1

R27

SECONDARY SECONDARY R31 E C30 THERMOSTATIC PRIMARY DISSIPATOR IGBT Q1 D21 D22 D23
DISSIPATOR DISSIPATOR CAPSULE D20 SECONDARY DIODES

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 TECNICA 1400 - 1600

ELENCO PEZZI DI RICAMBIO - LISTE PIECES DETACHEES

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

13

11

15

12

21

16

24

19 25

23 20

7 1

2 6

4 3

10 8

22 9

18 14 5 17
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

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 TECNICA 1400 - 1600
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 Trasformatore Potenza Diodo Trasformatore
Potentiometre Trasformateur Puissance Diode Transformateur
1 Potentiometer
Potentiometer
9 Power Transformer
Leistungstransformator
17 Diode
Diode
25 Transformer
Transformator
Potenciometro Transformador De Potencia Diodo Transformador
Interruttore Pressacavo Kit Igbt + Diodo
Interrupteur Presse Cable Kit Igbt + Diode
2 Switch
Schalter
10 Cable Bushing
Kabelhalter
18 Kit Igbt + Diode
Kit Igbt + Diode
Interruptor Prensa Cable Kit Igbt + Diodo
Scheda Controllo Fibbia Per Cinghia Kit Scheda Completa
Platine De Control Boucle Pour Courroie Kit Platine Complete
3 Control Pcb
Steurungskarte
11 Belt Buckle
Gurtschnalle
19 Kit Complete Card
Kit Komplette Karte
Tarjeta De Controlo Hebilla Para Correa Kit Tarjeta Completa
Cavo Alimentazione Aggancio Per Cinghia Pwm Controller
Cable D'alimentation Accrochage Pour Courroie Pwm Controller
4 Mains Cable
Netzkabel
12 Belt Hook
Gurthaken
20 Pwm Controller
Pwm Controller
Cable De Alimentacion Gancho Para Correa Pwm Controller
Ventilatore Cinghia Kit Manopola
Ventilateur Courroie Kit Poignee
5 Fan
Ventilator
13 Belt
Gurt
21 Knob Kit
Griff Kit
Ventilador Correa Kit Manija
Raddrizzatore Fondo Condensatore
Redresseur Chassis Condensateur
6 Rectifier
Gleichrichter
14 Bottom
Bodenteil
22 Capacitor
Kondensator
Rectificador Fondo Condensador
Induttanza Filtro Mantello Resistenza
Inductance Filter Capot Resistance
7 Filter Inductance
Filter Drossel
15 Cover
Deckel
23 Resistor
Widerstand
Induccion Filtro Panel De Cobertura Resistencia
Induttanza Presa Dinse Rele'
Inductance Prise Dix Relais
8 Inductance
Drossel
16 Dinse Socket
Dinse Steckdose
24 Relais
Relais
Induccion Enchufe Dinse Relais

Technical repair sheet:

To improve our service, on completing each repair we request all Service Centres to complete the technical
repair sheet as on the next page, and return it to Telwin.

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 TECNICA 1400 - 1600
Official servicing centers
Repairing card
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
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
ISO
Fax +39 - 0445 - 858800 / 858801 9001
E-mail: telwin@telwin.com http://www.telwin.com CERTIFIED QUALITY SYSTEM

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