Telwin TECHNOLOGY TIG 172 Istruzioni operative
cod. 988647
inverter
TECHNOLOGY TIG 172
AC/DC - HF/LIFT
TROUBLESHOOTING
AND REPAIR MANUAL
TROUBLESHOOTING
AND REPAIR MANUAL
“reparation no problem !”
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
15
TECHNOLOGY TIG 172 AC/DC
-2-
TIG & MMA
CYCLE CONTROL
31
678
245
1
13
17
33
11
3
23
29
32
30
34
12
19
V
t
16
20
PROTEZIONE
SOVRATENSIONE
V
t
14
IGBT DRIVER
21
SEPARAZIONE
GALVANICA
22
INDUCTANCE
THERMOSTAT
27
SCR DRIVER
25
SHUNT AMPLIFIER
+|
26
MAXIMUN
CURRENT REGOLATOR
18
CONTROL PANEL
24
10
+
-
9
AC/ DC CURRENT
CONVERTER
28
BLOCK DIAGRAM
OPERATION AND WIRING DIAGRAMSOPERATION AND WIRING DIAGRAMS
OPERATION AND WIRING DIAGRAMSOPERATION 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
TORCH BUTTON
SOLENOID VALVE
RELAY
HF GENERATOR
SOLENOID VALVE
TORCH BUTTON
RELAY
AUXILIARY
TRANSFORMER
SECONDARY
DIODE THERMOSTAT
OUTPUT
INPUT
-3-
ANALYSIS OFTHE BLOCK DIAGRAM
Block 1
Block 2
Block 4
Block 5
Block 6
Block 7
NOTE:Unless indicated otherwise, it should be assumed that
thecomponentsareassembledontheweldingmachine.
Consistingof:C3,C8,C9,L1 .
Preventsnoisefromthemachine frombeingtransmittedalong
themainpowerlineandviceversa.
Consistingof:D3,D5 .
Convertsthe mains alternating voltageinto continuous pulsed
voltage.
Consistingof:C2,C4,C5,C6,C7 .
Converts the pulsed voltage from the rectifier bridge into
continuousvoltage.
Consistingof:Q1,Q2 .
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.
Consistingof:T2.
TheC.T.isusedtomeasurethecurrentcirculatinginthepower
transformer primary and transmit the information to block 14
(primarycurrentreaderandlimiter).
Consistingof: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
supplyline).
EMC Filter
Rectifier bridge
Filter
Chopper
Current transformer
Power transformer
(primaryboard)
(primaryboard)
Consistingof:K1,K2,R1(primaryboard).
Prevents the formation of high transient currents that could
damage the main switch, the rectifier bridge and the
electrolyticcapacitors.
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 relays
willbeenergised.
(primaryboard)
(primaryboard)
(primaryboard)
Consisting of: D1, D2, D3, D4, D5, D6, D7, D8, D9, D10
(secondaryboard)
D1, D2 convert the current circulating in the positive OUT of
the power transformer to a single direction, preventing
saturationofthenucleus.
D3, D4, D5 recirculate the inductance output current (block 9)
during the time when the IGBT's are not conducting,
bypassingthepowertransformer(block7).
Block 3
Block 8
Pre-charge
Secondary diodes
Positivepolaritydiodesinthecircuit:
Negativepolaritydiodesinthecircuit:
D9, D10 convert the current circulating in the negative OUT of
the power transformer to a single direction, preventing
saturationofthenucleus.
D6, D7, D8 recirculate the inductance output current (block 9)
duringthetimewhentheIGBT'sarenotconducting,bypassing
thepowertransformer(block7).
The positive polarity diodes in the circuit are
involved. The positive and negative polarity diodes in the
circuitareinvolvedalternately.
Consistingof:SCR(secondaryboard)
The SCR module is piloted by block 18 (microcontroller) and
block 27 (SCR driver), transforming the secondary output
currentfromDCtoACwhenTIGACweldingisrequired.
Consistingof:L1,R2,(secondaryboard)
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 25 (shunt amplifier), which will process it.
(primaryboard)
(primaryboard)
Consistingof:D16,R81,R82,R83,R84,R85(controlboard).
Detectsandlimitsthesignal from block6 (current transformer)
and, via trimmer R85, adjusts the maximum allowable primary
current. The signal is also redimensioned so that it can be
processedandcomparedinblock16(dutycyclemaker).
Consistingof:U14(controlboard).
Processes the information arriving from block 17 (adder) and
block 15 (primary current reader and limiter), producing a
square wave with variable duty cycle, limiting in any case the
primarycurrenttoamaximumpresetvalue.
DC Operation:
AC Operation
Block 9
Block 10
Block 15
Block 16
Primary current reader and limiter
Duty cycle maker
AC/DC current converter
Inductance and Shunt
Secondary EMC Filter
HF Transformer
Flyback power supply
IGBT Driver
Block 11
Block 12
Block 13
Block 14
Consistingof: CY1.
Prevents noise from the power source from being transmitted
throughtheweldingcablesandviceversa.
Consistingof:T2.
The HF transformer boosts the signal from block 34 (hf power
source), raising the voltage impulse in the secondary at the
instantwhenarcstrikeisgenerated.
Italsoisolatestheweldingcircuitfromtheprimarycircuit
Consistingof:T2,U2 .
Uses switching methods to transform and stabilise the voltage
obtained from block 4 (filter) and supplies auxiliary voltage to
powerblock14(driver)andthecontrolboardcorrectly.
Consistingof:ISO1,ISO2 ..
Takes the signal from block 13 (flyback power supply) and,
controlled by block 16 (duty cycle maker), makes the signal
suitableforpilotingblock6(chopper).
TECHNOLOGY TIG 172 AC/DC
-4-
Block 26
Block 27
Block 28
Block 29
Block 31
Block 32
Block 33
Block 35
Maximum current regulator
SCR Driver
Auxiliary transformer
Torch button
Solenoid valve relay and HF
Solenoid valve
HF generator
Consisting of: R105 (control board).
Processes the information arriving from block 25 (shunt
amplifier) and, via trimmer R105, allows calibration of the
maximum welding current that can be supplied by the power
source. The signal is re-dimensioned so that it can be
processedandcomparedwithblock17(adder).
Consisting of: ISO1,ISO5, Q1, Q2 and ISO2, ISO6, Q3, Q4
(secondaryboard)
Receives the signals arriving from block 18 (microcontroller)
and makes them appropriate for piloting block 9 (AC/DC
currentconverter).
Consisting of:T1, D2 (torch button board).
Its purpose is to supply a redimensioned, rectified voltage to
power block 30 (torch button relay).
(torchbuttonboard).
Consisting of:TIG Torch
When the torch button is operated, a separate signal is sent to
block 18 (microcontroller), to achieve arc strike and enable the
solenoidvalve.
Consisting of: K2 (secondary board).
When the torch button is pressed, block 18 (microcontroller)
activates relay K2 which supplies the mains voltage needed to
powerblock33(solenoidvalve)andblock34(HFgenerator).
Consisting of:Y1
Supplies an appropriate amount of the desired gas mixture
to strike the arc in the torch and the quantity needed to
operate and cool the torch itself.
Consisting of: HF generator board
Using the signal sent by block 32 (s ), the
generator produces a high frequency signal that is sufficient
for powering block 12 (HF transformer).
olenoid valve relay
Fan
HF safeguard
Consistingof:V1.
Powered directly by block 13 (flyback transformer) and cools
thepowercomponents.
Consistingof: K1,R1
The HF safeguard also separates the control board from the
high frequency so as to prevent the residual signal from the
torchbuttoncablesfromenteringtheboard.
Block 30
TECHNOLOGY TIG 172 AC/DC
Block 17
Block 18
Block 21
Block 22
Block 23
Block 24
Block 25
Adder
Microcontroller
Galvanic separation
Inductance thermostat
Secondary diode thermostat
Control panel
Shunt Amplifier
Consistingof:U13A,U13B(controlboard).
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).
Consistingof:U4(controlboard)
Control logic, which manages typical timing for the TIG and
MMA cycles. Also drastically limits power source output
currentwhen itdetectsanalarm event.Intheeventofanalarm
it acts directly on block16 (duty cycle maker) and directly
changes the reference signal obtained from block 23 (control
panel).
Consistingof:U3A,R62,U68(primaryboard).
Consistingof:U3B,R61,U67(primaryboard).
Consistingof:ISO3(primaryboard).
The signal arriving from blocks 19 and 20 (over- and under-
voltage safeguard) is separated galvanically and sent to block
18(microcontroller)fordetectionofapossiblealarmevent.
Consistingof:ST2.
When the temperature of the inductance is too high the
thermostat cuts in, sending an alarm signal to block 18
(microcontroller). It is reset automatically when this alarm
conditionisnolongerpresent.
Consistingof:ST1(secondaryboard).
Whenthetemperatureofthesecondarydiodedissipatoristoo
highthethermostatcutsin,sendinganalarmsignaltoblock18
(microcontroller). It is reset automatically when this alarm
conditionisnolongerpresent.
Consistingof:Controlpanelboard
Panel for setting and displaying the parameters and operating
modes of the power source, all controlled by block 18
(microcontroller).
Consistingof: U12(controlboard).
Amplifies the signal arriving from block10 (shunt inductance),
and makes it appropriate for block 26 (maximum current
regulator).
Block 19
Block 20
Undervoltage safeguard
Overvoltage safeguard
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
safeguardtriggers).
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).
(14)
IGBT
DRIVER
(5)
CHOPPER
(18)
MICROCONTROLLER
(17)
ADDER
(26)
MAXIMUN CURRENT
REGULATOR
(25)
AMPLIFIER
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
(8)
SECONDARY
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
-7-
TECHNOLOGY TIG 172 AC/DC
WIRING DIAGRAMS
General wiring diagram
-8-
TECHNOLOGY TIG 172 AC/DC
Wiring diagram primary board - Power
Wiring diagram primary board - Driver
-9-
TECHNOLOGY TIG 172 AC/DC
Wiring diagram control board - Micro
Wiring diagram primary board - power supply
-10-
TECHNOLOGY TIG 172 AC/DC
Wiring diagram control board - Digital
Wiring diagram control board - Analogyc
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