Escolar Documentos
Profissional Documentos
Cultura Documentos
988241
inver ter
GENERATOR
GENERATOR OPERATION
OPERATION
AND
AND WIRING
WIRING DIAGRAMS
DIAGRAMS
TECHNOLOGY 145-165-200
Block diagram
EMC FILTER
VARISTOR
RECTIFIER
BRIDGE
PRECHARGE
FILTER
CHOPPER
T.A.
MAIN
TRANSFORMER
SECONDARY
CIRCUIT
DIODES
REACTANCE
SHUNT
SECONDARY
EMC
FILTER
10
11
12
DRIVER
PRIMARY CURRENT
DETECTOR AND
REGULATOR
SHUNT
AMPLIFIER
POWER SUPPLY
UNIT
OVERVOLTAGE
PROTECTION
13
19
ALARM BLOCK
UNDERVOLTAGE
PROTECTION
17
14
DIODE
THERMOSTATIC
CAPSULE
DUTY CYCLE
PULSE
GENERATOR
18
ADDER
28
21
HOT START
15
25
THERMOSTATIC
CAPSULE ON
INDUCTANCE
DUTY CYCLE
LIMITER
16
AUXILIARY
POWER
SUPPLIES
20
MAXIMUM
OUTPUT
CURRENT
REGULATOR
22
SHORT
CIRCUIT
DETECTOR
FORCED ARC
29
23
POTENTIOMETER
ALH = +28
ALL = +28
ALP = +12
ALM = -12
30
26
SHORT
CIRCUIT
SWITCH-OFF
24
27
electrolytic capacitors.
Block 1
Block 5
EMC filter
Filter
Block 6
Block 2
Chopper
Varistor
Consists of RV1
Prevents spikes from the line with amplitude over 400V entering
the inverter.
Block 7
Block 3
T.A.
Rectifier bridge
Consists of T1.
This current transformer measures the primary current and
transmits the information to Block 18 (duty cycle pulse generator).
Block 4
Block 8
Primary current detector and regulator
Precharge
Consists of K1, K2, R34.
When the inverter is switched on, the relays K1 and K2 are deenergised and the capacitors C33-C37 are charged via R37.
When the capacitors are charged, the relays are energised.
This block prevents the formation of high transient currents which
could damage the mains switch, the rectifier bridges and the
Consists of:
(D1, R2, R55, R56, R57), R44.
Detects and limits in amplitude the signal from Block 7; via R44 the
maximum permitted primary current is regulated.
2
TECHNOLOGY 145-165-200
3. Undervoltage at output
4. Overvoltage at output
5. Short circuit at output for more than 1.5 seconds (Antistiking
function).
Block 9
Main transformer
Consists of (tr1).
Reduces the mains voltage, via chopper block, from 320V to
100V and galvanically separates the primary from the secondary
circuit.
Block 18
Duty cycle pulse generator
Consists of: (U2 = UC 3842).
Processes the information produced by Block 25 (adder), by Block
7, 8 (measurement of primary current), by Block 17 (alarms) and
produces a square wave at the output with variable duty cycle
(from 0 to 47%).
Block 10
Secondary circuit diodes
Consists of D1 - 2 - 3 - 4 - 5
D1 - 2: eliminate the negative part of the secondary circuit voltage.
D3 - 4 - 5: during the IGBT non-conduction period, these diodes
recirculate the output inductance current.
Block 19
Driver
Consists of: Iso 4, Iso 5, Q1, Q2, Q3, Q4.
Galvanically separates and amplifies in current the square wave
produced by Block 18.
Block 11
Reactance, shunt
Block 20
Consists of L R2.
The reactance levels the secondary diodes output current making
it a direct current; the shunt reads this current which is then
processed by the adder block.
Shunt amplifier
Consists of: (U4).
Amplifies the signal from the shunt.
Block 12
Secondary EMC filter
Block 21
Consists of CA, CB .
Prevents the disturbances from the inverter spreading in the
welding cables and viceversa.
Block 13
Overvoltage protection
Block 22
Hot start
Block 14
Undervoltage protection
Block 23
Forced arc
Consists of: (Q6, Q7, C14).
If the arc voltage drops below 10V, this stage produces a
temporary increase in the output current.
Block 15
Diode thermostatic capsule
Block 24
Potentiometer
Consists of: R48.
By turning the potentiometer clockwise, the voltage on the cursor
varies from 0 to 5V which corresponds proportionally to the
inverter output current.
Block 16
Thermostatic capsule on inductance
Block 25
Adder
Consists of: (U1A, U1B).
Processes the information from Blocks 20-21-22-23-24 and sends
it to the duty cycle pulse generator (Block 17).
Block 17
Alarm block
Consists of: Q10, R48, D26, (D12, D13,Q1).
Sends a lock signal to Block 18 (switches the inverter off) and
indicates that an alarm has cut in via the yellow led D26 on the
front panel.
This led comes on when:
1. The thermostatic capsule has cut in on the diodes.
2. The thermostatic capsule has cut in on the inductance.
Block 26
Short circuit detector
Consists of (U3B).
If the welding voltage is below 10V, this circuit causes the forced
arc to cut in (Block 22).
3
TECHNOLOGY 145-165-200
output or if the inverter has locked out (e.g. due to over or
undervoltage, antistiking, thermostatic capsule).
Block 27
Short circuit switch-off
Block 29
Block 28
12V power supply unit
Block 30
Auxiliary power supplies
Illustrated references
(13, 14)
Over/undervoltage
(8, 17, 18, 20, 22, 23, 25, 26, 27, 28, 29)
Module SMD
(24)
Potentiometer
Switching power
supply unit
(21)
Secondary
circuit
current max regulation
(8)
(4)
(7)
Primary
Pre-charge TA
current limitation
(3)
Rectifier
bridge
(5)
Filter
(19)
Driver
(2)
Varistor
(6)
Chopper
IGBT
(1)
EMC
Filter
(6)
Chopper
IGBT
TECHNOLOGY 145-165-200
(10)
(11)
Shunt
(10)
(15)
(12)
D3, 4, 5
Thermostatic
capsule
Secondary
EMC filter
(9)
Transformer
(16)
Capsule
on reactance
(11)
Reactance
CONTROL
BOARD
PRIMARY
CIRCUIT
BOARD
SECONDARY
CIRCUIT
BOARD
TECHNOLOGY 145-165-200
General wiring diagram
C39
4.7n275VacYP10
FASTONM
PE
CN7
FASTONM
1
2
3
4
5
6
7
8
9
10
11
12
PANDUIT100-12
J3
ALP12
AL0
ALM12
ALP5
RIF
POT
BLAK
CC
FUNZ
IOUT
VOUT
+5
FASTONM
CN10
FASTONM
CN3
FASTONM
CN2
C40
4.7n275VacYP10
FASTONM
CN7A
CN11
FASTONM
CN9
FASTONM 1u275VacX2P27.5
C32
R50
1M0.5W
L1
INDUCTORCOUPLED
FASTONM
CN8
H5
DISS. SU STRUTTURA
LF1
CN5
L2
FASTONM
L1
CN4
CN2
FASTONM
LF2
D19
36MB80A
REL-
D22
36MB80A
V275LA40
RV1
CN1
FASTONM
MAX
47KRV20CM
R42
REL+
ALM12
1
2
3
4
5
R43
POT10KPIHERPC16
C36
27R
R37
27R
R36
C35
OUTOUT+
SH+
THTH+
DRL-
DRL+
470RV20CM
R44
IPLIM
TA-
DR+
DR-
TA+
PPR+
10R
R51
27R
R41
27R
R40
470u400VSNAPIN3550
470u400VSNAPIN3550
C33
ALP5
ALP12
Q6
+5
SW1
RIF
POT
BLAK
TMAX1
TMAX2
IPLIM1
IPLIM2
CC
FUNZ
IOUT
VOUT
ALP12
Q8
470u400VSNAPIN3550
C34
470u400VSNAPIN3550
DRH-
DRH+
PANDUIT100-5
J1
JP2
JUMPER
TIG/MMA
AL0
.22u630VMKPP27.5
C37
RELE18V16A
K2
RELE18V16A
K1
220R5W
R34
SWITCH102
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
J2
Q9
HGTG30N60C3
R35
20R25W
C41
R45
120K
BLAK
VBUS-
C42
10n
10K
R48
2.2n630VMKPP10
C38
D20
RURP1560
VBUS+
ELBOMEC ML73/38
H9
RURP1560
D25
R38
20R5W
ALIMON
JUMPER
JP1
XF+
XF-
R49
2K2
ALP12
R46
1K0.5W
Q10
BC337
D26
LEDGIALLO
SECONDARIO
PRIMARIO
FASTONM
CN6
FASTONM
CN3
TA150320
T1
10n630VMKPP15
D23
RURP880
ELBOMEC ML73/38
H7
D21
RURP1560
10n630VMKPP15
C31
D18
RURP880
D24
RURP880
R39
20R25W
D17
RURP880
DISS. SU STRUTTURA
H8
Q7
HGTG30N60C3
DISS. SU STRUTTURA
H4
TA-
TA+
TECHNOLOGY 145-165-200
DR-
DR+
R3
220
C4
470pCERP5
C1
470pCERP5
R8
3K9
R2
3K9
3
8
3
ISO5
HCPL3101
ISO4
HCPL3101
ALL-
ALL+
ALH-
ALH+
C5
.1u
C2
.1u
R10
2R2
R5
2R2
Q4
BC327
Q3
BC337
Q2
BC327
Q1
BC337
C3
C6
2.2u25VTANT.
D6
10V
R9
2K2
4R7
R7
2.2u25VTANT.
D3
10V
R4
2K2
4R7
R1
R11
1K
R6
1K
D5
18V
D4
18V
D2
18V
D1
18V
DRL-
DRL+
DRH-
DRH+
TECHNOLOGY 145-165-200
Driver wiring diagram
VBUS-
VBUS+
R26
R30
22K1%
C30
1uMKTP5
270K0.5W
R27
220K0.5W
47K
R20
R32
15K1%
R17
4.3K1%
22K1%
R15
1K 1%
R31
C18
.1u
C13
47n
R33
27K 1%
R22
4K7
R24
43K1%
R19
150K
470pCERP5
C14
100u 50V
C10
1N4148
D10
OVLO
UVLO
C25
.1u
C20
1n63Vp5
8
4
6
1
LM393
U5B
LM393
U5A
UC3842AN
VREF
RT/CT
OUT
COMP
U1
C12
.1u
R29
1K5
3
ISEN 2
VFB 7
VCC
GND
R13
47K0.5W
R12
47K0.5W
R28
390R
R18
1K
CAPSULA SECONDARIO
JUMPER
JP3
NA
13
CNY17
ISO3
Q5
IRFBE30
NP
88
R25
1R2
BYV27-200
D14
D11
18V
R14
10K5WF
C24
22u25V
REL-
REL+
C19
470pCERP5
1K
R21
22R
R16
H1
ELBOMEC ML26AA
4.7n630VMKPP10
C11
D9
BA159
NSB
7
NS13
NS+
13
ND2
23
ND1
23
C15
10u50V
C9
10u50V
C7
PPR+
C22
1N4004
D15
IN
ELBOMEC ML26AA
H3
OUT
C16
4.7u25V
4.7u25V
U4
LM7805CT
OUT
OUT
C27
10u50V
C23
.1u
C17
.1u
SECONDARIO
PRIMARIO
ALM12
AL0
ALP12
C29
.1u
ALP5
ISOLAMENTO 3750V
C28
.1u
LM7912CT
U3
IN
IN
H2
ELBOMEC ML26AA
U2
LM7812CT
ALL-
ALL+
ALH-
ALH+
C26
470u25V
BYV27-200
D16
BYV27-200
D13
47u25V
C21
470u25V
BYV27-200
D12
BYV27-200
D8
BYV27-200
G
N
D
2
1
G
N
D
C8
.22u630VMKPP27.5
8
4
8
4
G
N
D
D7
TECHNOLOGY 145-165-200
OUT-
C4
1K
R40
1N4004
D15
R52
82K
100K
R49
R58
1K
C16
1nCER
1nCER
OUT+
SH+
TA-
R1
1K
C21
10n
330R
R45
100R
R41
C15
.1uCER
D3
9V1
D18
15V
D17
15V
FUNZ
.1uCER
C6
POT
15K
R50
C18
.1uCER
C24
22p
IOUT
1N4148
C19
10n
R43
22K
D14
R25
10K
12
13
10
C23
.1uCER
+VCC
10K
R39
C17
.1uCER
U1D
LM324D
14
6K8
+VCC
U1C
LM324D
R24
CC
-VCC
IPLIM1
R57
39R
R10
100K
AMPLI
SHUNT
R56
39R
TMAX2
R55
39R
U4
LM308D
TMAX1
C11
100pCER
-VCC
-VCC
+VCC
R36
12K
R2
39R
POT
CORR.
4
8
7
1
1
1
1
1
VOUT
+5
2K2
R30
START
+5
R53
2K2
R44
5K1
Q7
BC337
R37
3K3
10K
R26
2K2
R13
RIF
1N4148
10
11
+VCC
C14
10u16V
C9
10u16V
R18
180K
Q6
BS170
CC
LM339D
13
LM324D
U1B
START
R54
3K3
+VCC
START
ARCFORCE
COMP.CORTO
U3D
COMP.
START
LM339D
U3B
1N4148
D7
C20
.1uCER
R16
47K
Q3
BC337
R22
3K3
4K7
R6
R34
22K
D11
+VCC
3
1
2
4
1
1
1K
R32
1N4148
D9
2K2
R14
R46
3K3
1N4148
D16
3
-
C13
.22u
4K7
R33
47K
R51
1nCER
D4
R9
22K
Q5
BC337
SPEGNIMENTO
CC
2K2
R31
4K7
R19
HOTSTART
Q2
BS170
IOUT
1N4148
D6
C7
R8
4K7
1nCER
R3
4K7
C8
AMPLIF.
ERRORE
4
1
1
1N4148
D2
1N4148
R28
120K
22u16V
C22
+5
R47
150K
+VCC
R35
15K
1N4148
D10
R23
10K
+VCC
1N4148
C5
4n7
U1A
LM324D
C1
C12
1nCER
33K
R12
BAT42
D19
COMP
OUT
RT/CT
VREF
14
TERMICO
FREQ
R21
1K
C3
4n7NPO
220R
R7
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
J2
DR+
+5
OUTOUT+
SH+
THTH+
PPR+
TATA+
AL0
ALM12
ALP5
ALP12
DR+
DRRIF
POT
BLAK
TMAX1
TMAX2
IPLIM1
IPLIM2
CC
FUNZ
IOUT
VOUT
ALLARME
Q1
BC337
47KRV20CM
R5
+VCC -VCC
150
BLAK
R17
6K8
R15
+5
C2
.1uCER
R48
3K3
D13
1N4148
1N4148
D12
R38
3K3
LIMIT. DUTY
+VCC
1
6
4
8
U3C
LM339D
22n
C26
UC3845AD8
U2
PROT. PRIMARIO
LM339D
U3A
TH-
22K
R11
GND
VCC
VFB
ISEN
TH+
7
2
3
PPR+
1N4148
D5
+VCC
.1uCER
100pCER
C25
IPLIM2
R4
22K
TA+
3
1
2
10
1
2
1
2
+
D1
TECHNOLOGY 145-165-200
SMD module wiring diagram
11
J4
INSERTO
XFS-
J2
INSERTO
XFS+
RURU8060
R4
10R5WF
C2
1n5 630V MKP K P15
D2
D1
D4
RURU8060
D3
HEATSINK
H1
D5
OUT+
SHUNT 1.1mOhm
R2
SH+
J3
INSERTO
J1
FASTON
TECHNOLOGY 145-165-200
ISO
9001
SINCERT
Deutscher
Akkreditierungs
Rat
R
TGA-ZQ-002/92-00