Tecnica_144-164.pdf
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1902 KB
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Pobierz
cod. 988637
TECNICA144-
164
TECNICA140.1
-142
inverter
TROUBLESHOOTING
TROUBLESHOOTING
TROUBLESHOOTING
TROUBLESHOOTING
AND REPAIR MANUAL
AND REPAIR MANUAL
AND REPAIR MANUAL
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......................................................
9
Equipment required
9
General repair instructions
10
Troubleshooting and remedies
10
Testing the machine
13
Illustrations
15
SPARE PARTS LIST...............................................18
REPAIR SHEET...................................................... 20
“reparation no problem !”
TECNICA 144 - 164
OPERATION AND WIRING DIAGRAMS
BLOCK DIAGRAM
-2-
TECNICA 144 - 164
ANALYSIS OF THE BLOCK DIAGRAM
NOTE:
Unless indicated otherwise, it should be assumed that
the components are assembled on the power board.
Block 9
Inductance
Consisting of: L1.
Levels the secondary board diodes’ output current making it
practically continuous.
Block 1
EMC Filter
Block 10
Consisting of: C1, T4, C8, C15.
Prevents noise from the machine from being transmitted along
the main power line and vice versa.
Secondary EMC Filter
Consisting of: C28, C33.
Prevents noise from the power source from being transmitted
through the welding cables and vice versa.
Block 2
Pre-charge
Block 11
Consisting of: PD1, R4.
Prevents the formation of high transitory currents that could
damage the main power switch, the rectifier bridge and the
electrolytic capacitors.
When the power source is switched on the relay PD1 is de-
energised, capacitors C21, C22, C27 are then charged by R4.
When the capacitors are charged the relay is energised.
Voltage rectifier
Consisting of: D11,C18.
Rectifies and filters the voltage from the tertiary winding of the
power transformer (block 7).
Block 12
Auxiliary power supply trigger
Block 3
Consisting of: R18, R35, C20.
Via the resistors, the power source supplies the necessary
voltage to power block 13 (power supply).
Rectifier bridge
Consisting of: PD1.
Converts the mains alternating voltage into continuous pulsed
voltage.
Block 13
Block 4
Auxiliary power supply
Filter
Consisting of: U3, C17.
Stabilises the voltage at 12Vdc for the power arriving from
block 12 (auxiliary power supply trigger) and from block 11
(voltage rectifier).
Consisting of: C21, C22, C27.
Converts the pulsed voltage from the rectifier bridge into
continuous voltage.
Block 5
Block 14
Chopper
Driver
Consisting of: Q5, Q8.
Converts the continuous voltage from the filter into a high
frequency
Consisting of: Q6, D19, D23, Q7, D27, D26
Picks up the signal arriving from block 15 (separator
transformer) and under the control of block 17 (transformer
pilot) adjusts it to suit piloting of block 5 (chopper).
square
wave
capable
of
piloting
the
power
transformer.
Regulates the power according to the required welding
current/voltage.
Block 15
Block 6
Separator transformer
Current transformer
Consisting of: T1.
Supplies two signals, which are separated galvanically from
one another, that will be sent to power block 14 (driver).
Consisting of: T2.
The C.T. is used to measure the current circulating in the
power transformer primary and transmit the information to
block 17 (primary current reader and limiter).
Block 16
Block 7
Transformer Pilot
Power transformer
Consisting of: Q4, D20, D22, D24.
Amplifies the signal arriving from block 18 (duty cycle maker),
needed to pilot block 15 (separator transformer).
Consisting of: T3.
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 17
Primary current reader and limiter
Consisting of: D2, R25.
Reads the signal from block 6 (current transformer) and scales
it down so it can be processed and compared in blocks 18 and
19.
Block 8
Secondary diodes
Consisting of: D32, D33, D34 .
D34 converts the current circulating in the transformer to a
single direction, preventing saturation of the nucleus.
D32, D33 recirculate the inductance output current (block 9)
when the IGBT's are not conducting, bypassing the power
transformer (block 7).
Block 18
Duty cycle maker
Consisting of: U1.
Processes the information from block 19 (adder) and block 17
(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.
-3-
TECNICA 144 - 164
Block 19
Block 27
Adder
Undervoltage safeguard
Consisting of: R39, R64, U2B .
If the main supply voltage falls below the minimum allowed
value this safeguard triggers (a tolerance of approx. ±15% of
the power supply voltage is allowed: outside this range the
safeguard triggers).
Consisting of: U2C.
Gathers all the information from block 17 (primary current
reader and limiter), from block 20 (alarms) and from block 22
(current potentiometer), and produces a signal with a suitable
voltage for processing by block 18 (duty cycle maker).
Block 20
Block 28
Alarm Block
Power supply LED
Consisting of: Q3, R43, R44, R38, R36
When an alarm is detected the power source output current is
drastically reduced by making direct adjustments to block 18
(duty cycle maker) and directly changing the reference signal
obtained from block 22 (current potentiometer).
Consisting of: D10.
Indicates when the power source is correctly powered and
ready for use.
Block 29
Fan
Block 21
Consisting of: V1.
Powered directly by block 13 (flyback transformer) and cools
the power components.
Alarm LED
Consisting of: D12.
It is switched on by block 20 (alarms) in the event of:
1) Triggering of thermostatic capsule/thermostat on power
transformer.
Triggering due to undervoltage.
3) Triggering due to overvoltage.
4) Short circuit at output (electrode holder clamp and earth
cable connected to one another or electrode stuck to piece
being welded).
2)
Block 22
Current potentiometer
Consisting of: R23.
This is used to set the reference voltage needed to adjust the
output current: when the potentiometer knob is turned the
cursor voltage varies, thus varying the current from the
minimum to the maximum value.
Block 23
Maximum current adjustment
Consisting of: JP1, JP2, JP3.
Used to adjust the maximum cutting current to be supplied by
the power source.
Block 24
Power transformer thermostat
Consisting of: ST1.
When the temperature of the power transformer is too high,
this safeguard is triggered. It is reset automatically after the
alarm condition has ceased.
Block 25
Galvanic separation
Consisting of: ISO1.
The signal arriving from blocks 24 (power transformer
thermostat) is separated galvanically and sent to block 20
(alarms) for detection of a possible alarm event.
Block 26
Overvoltage safeguard
Consisting of: R1, R5, R14, R19, R24, R29, U2A.
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).
-4-
TECNICA 144 - 164
ILLUSTRATIONS
Power boad
(18)
DUTY CYCLE
MAKER
(1)
PRIMARY EMC
FILTRE
(12)
AUXILIARY POWER
SUPPLY TRIGGER
(13)
AUXILIARY POWER
SUPPLY
(3)
RECTIFIER
BRIDGE
(2)
PRE-CHARGE
(19)
ADDER
(4)
FILTER
(22)
CURRENT
POTENTIOM.
(28)
POWER
SUPPLY
LED
(5)
CHOPPER
(21)
ALARM
LED
(15)
TRANSFORMER
SEPARATOR
(6)
POWER
TRANSFORMER
(9)
INDUCTANCE
(10)
SECONDARY
FILTER EMC
(14)
DRIVER
(8)
SECONDARY
DIODES
(5)
CHOPPER
(7)
POWER
TRANSFORMER
-5-
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