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cod. 988241
inver ter
GENERATOR OPERATION AND WIRING DIAGRAMS
GENERATOR OPERATION AND WIRING DIAGRAMS
“ t r o u b l e - f r e e r e p a i r ”
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2
1 2
13 19 20 288
3 4 5 6 7 9 10 11 12
EMC FILTER VARISTOR
OVERVOLTAGE
PROTECTION
DRIVER SHUNT
AMPLIFIER
POWER SUPPLY
UNIT
PRIMARY CURRENT
DETECTOR AND
REGULATOR
14 18 21
UNDERVOLTAGE
PROTECTION
DUTY CYCLE
PULSE
GENERATOR
MAXIMUM
OUTPUT
CURRENT
REGULATOR
17
ALARM BLOCK
15 25 22
DIODE
THERMOSTATIC
CAPSULE
ADDER HOT START
16
30
29 23 26
24 27
THERMOSTATIC
CAPSULE ON
INDUCTANCE
AUXILIARY
POWER
SUPPLIES
DUTY CYCLE
LIMITER
FORCED ARC SHORT
CIRCUIT
DETECTOR
POTENTIOMETER SHORT
CIRCUIT
SWITCH-OFF
RECTIFIER
BRIDGE
PRECHARGE FILTER CHOPPER T.A. MAIN
TRANSFORMER
SECONDARY
CIRCUITDIODES
REACTANCE
SHUNT
SECONDARY
EMCFILTER
ALH = +28
ALL = +28ALP = +12
ALM = -12
Block 1
EMC filter Consists of C32, C39, C40, L1, R50.Prevents the disturbances from the inverter spreading through theline and viceversa.
Block 2
Varistor Consists of RV1Prevents spikes from the line with amplitude over 400V enteringthe inverter.
Block 3
Rectifier bridgeConsists of D19, D22.Converts the alternating mains voltage into direct pulsatingvoltage.
Block 4
PrechargeConsists of K1, K2, R34.When the inverter is switched on, the relays K1 and K2 are de-energised 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 whichcould damage the mains switch, the rectifier bridges and the
electrolytic capacitors.
Block 5
Filter Consists of C33, C34, C35, C36, C37.Converts the pulsating voltage from the rectifying bridge intodirect voltage.
Block 6Chopper Consists of Q6, Q7, Q8, Q9.Converts the direct voltage from the filter into a square wave athigh frequency (32 khz) for driving the transformer.
Block 7
T.A.Consists of T1.This current transformer measures the primary current andtransmits the information to Block 18 (duty cycle pulse generator).
Block 8
Primary current detector and regulator Consists of:(D1, R2, R55, R56, R57), R44.Detects and limits in amplitude the signal from Block 7; via R44 themaximum permitted primary current is regulated.
Block diagram
The components between () belong to the controle module SMD
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3
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 secondarycircuit.
Block 10
Secondary circuit diodesConsists of D1 - 2 - 3 - 4 - 5D1 - 2: eliminate the negative part of the secondary circuit voltage.D3 - 4 - 5: during the IGBT non-conduction period, these diodesrecirculate the output inductance current.
Block 11
Reactance, shunt Consists of L R2.The reactance levels the secondary diodes output current makingit a direct current; the shunt reads this current which is thenprocessed by the adder block.
Block 12
Secondary EMC filter Consists of CA, CB .Prevents the disturbances from the inverter spreading in thewelding cables and viceversa.
Block 13
Overvoltage protectionConsists of: U5 A, R31, R33.If the supply voltage exceeds 265 Vac, the chopper is switched off.
Block 14
Undervoltage protectionConsists of U5B, R30, R32.If the supply voltage is below 110V, the chopper is switched off.
Block 15
Diode thermostatic capsuleConsists of: Capsule S1.If the temperature on the diodes exceeds 70 degrees, the chopperis switched off.
Block 16
Thermostatic capsule on inductanceConsists of: capsule S2.If the temperature of the inductance exceeds 130 degrees, theinverter is switched off.
Block 17
Alarm blockConsists of: Q10, R48, D26, (D12, D13,Q1).
Sends a lock signal to Block 18 (switches the inverter off) andindicates that an alarm has cut in via the yellow led D26 on thefront 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.
3. Undervoltage at output4. Overvoltage at output5. Short circuit at output for more than 1.5 seconds (Antistiking
function).
Block 18
Duty cycle pulse generator Consists of: (U2 = UC 3842).Processes the information produced by Block 25 (adder), by Block7, 8 (measurement of primary current), by Block 17 (alarms) andproduces a square wave at the output with variable duty cycle(from 0 to 47%).
Block 19
Driver Consists of: Iso 4, Iso 5, Q1, Q2, Q3, Q4.Galvanically separates and amplifies in current the square waveproduced by Block 18.
Block 20Shunt amplifier Consists of: (U4).Amplifies the signal from the shunt.
Block 21
Maximum output current regulator Consists of: R 42.Permits reduction or increase in amplification of Block 20.
Block 22
Hot start Consists of: (Q2, Q3, C9).When the electrode touches the piece for the first time (beginningof welding), this block increases the current set by thepotentiometer in order to prepare the welding pool.
Block 23
Forced arc Consists of: (Q6, Q7, C14).If the arc voltage drops below 10V, this stage produces atemporary increase in the output current.
Block 24
Potentiometer Consists of: R48.By turning the potentiometer clockwise, the voltage on the cursorvaries from 0 to 5V which corresponds proportionally to theinverter output current.
Block 25
Adder Consists of: (U1A, U1B).Processes the information from Blocks 20-21-22-23-24 and sendsit to the duty cycle pulse generator (Block 17).
Block 26
Short circuit detector Consists of (U3B).If the welding voltage is below 10V, this circuit causes the forcedarc to cut in (Block 22).
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4
(1)EMCFilter
(6)Chopper
IGBT
(19)Driver
(3)Rectifierbridge
(7)TA
(4)Pre-charge
(8)Primary
current limitation
Switching powersupply unit
(24)Potentiometer
(6)Chopper
IGBT
(2)Varistor
(5)Filter
(21)Secondary
circuitcurrent max regulation
(13, 14)Over/undervoltage
(8, 17, 18, 20, 22, 23, 25, 26, 27, 28, 29)Module SMD
Block 27
Short circuit switch-off Consists of: (U3A).When the output short circuit persists for more than 2 seconds,this circuit switches the inverter off via Block 16.
Block 28
12V power supply unit Consists of R45, D15.Provides an output voltage of 12V which is present even when theinverter is not working (e.g. cut-in of thermostatic capsule) andenables Block 25 to detect whether there is a short circuit at the
output or if the inverter has locked out (e.g. due to over orundervoltage, antistiking, thermostatic capsule).
Block 29
Duty cycle limiter Limits the machine duty cycle during no-load operation.
Block 30
Auxiliary power suppliesIn order to reduce the dimensions and weight of the inverter, aswitching power supply unit has been used with an operatingprinciple similar to that of the chopper.The voltages that can be measured at its outputs are the following:
Illustrated references
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(11)
Shunt(10)
Secondary circuit diodes
(15)
Thermostaticcapsule
(12)
SecondaryEMC filter
(10)
D3, 4, 5
(9)Transformer
(16)Capsule
on reactance
(11)Reactance
5
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General wiring diagram
6
A B
C O N T R O L
B O A R D
P R I M A R Y
C I R C U I T
B O A R D
S E C O N D A R Y
C I R C U I T
B O A R D
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Primary circuit board wiring diagram
7
I G
B T :
I R G 4 P C 4 O U v e r s
i o n
1 4 5
R e
l a y
K 2 o n
l y v e r s
i o n
1 6 5 - 2
0 0
B r i
d g e
D 1 9 o n
l y v e r s
i o n
1 6 5 - 2
0 0
C 3 6 o n
l y v e r s
i o n
1 6 5 - 2
0 0
D R L +
D R L -
D R H +
D R H -
R E
L +
R E
L -
T A +
T A -
V B U S +
V B U S -
T A -
A L 0
A L M 1 2
A L P 5
D R +
D R -
A L P 1 2
T A +
P P R +
X F +
X F -
L 1
L 2 P
E
M A X
I P L I M
+ 5
L F 2
L F 1
P R I M A R I O
S E C O N D A R I O
A L I M O N
T I G / M M A
+ 5
O U T -
O U T +
S H +
T H -
T H +
A L P 1 2
A L P 1 2
T M A X 2
T M A X 2
I P L I M 1
A L P 1 2
B L A K
R I F
T M A X 1
I P L I M 2
I P L I M 2
B L A K
B L A K
B L A K
A L P 5
A L M 1 2
A L M 1 2
A L 0
A L 0
R I F R I F
A L P 1 2
A L P 1 2
V O U T
V O U T
I O U T
I O U T
F U N Z
F U N Z
C C
C C
P O T
P O T
R 4 0
2 7 R
C 3 7
. 2 2 u 6 3 0 V M K P P 2 7 . 5
T 1
T A 1 5 0 3 2 0
D 1 9
3 6 M B 8 0 A
- +
H 8 D
I S S .
S U S T R U T T U R A
D 2 1
R U R P 1 5 6 0
C 3 2
1 u 2 7 5 V a c X 2 P 2 7 . 5
2 0 R 5 W
R 3 8
R 3 5
2 0 R 2 5 W
C 3 5
4 7 0 u 4 0 0 V S N A P I N
3 5 5 0
R 3 4
2 2 0 R 5 W
C 3 9
4 . 7 n 2 7 5 V a c Y P 1 0
R 3 9
2 0 R 2 5 W
D 1 7
R U R P 8 8 0
R 3 6
2 7 R
D 2 3
R U R P 8 8 0
Q 8
H G T G 3 0 N 6 0 C 3
C 4 1
1 0 n 6 3 0 V M K P P 1 5
D 2 5
R U R P 1 5 6 0
Q 9
C 3 3
4 7 0 u 4 0 0 V S N A P I N 3 5 5 0
D 2 4
R U R P 8 8 0
D 2 0
R U R P 1 5 6 0
Q 7
R V 1
V 2 7 5 L A 4 0
Q 6
H G T G 3 0 N 6 0 C 3
R 3 7
2 7 R
C 3 6
4 7 0 u 4 0 0 V S N A P I N 3 5 5 0
K 1
R E L E 1 8 V 1 6 A
K 2
R E L E 1 8 V 1 6 A
H 4 D
I S S .
S U S T R U T T U R A
C 4 0
4 . 7 n 2 7 5 V a c Y P 1 0
D 1 8
R U R P 8 8 0
C 3 1
1 0 n 6 3 0 V M K P P 1 5
R 4 1
2 7 R
C 3 8
2 . 2 n 6 3 0 V M K P P 1 0
F A S T O N M
C N 4
F A S T O N M
C N 5
C 3 4
4 7 0 u 4 0 0 V S N A P I N 3 5 5 0
D 2 2
3 6 M B 8 0 A
- +
F A S T O N M
C N 3
F A S T O N M
C N 6
F A S T O N M
C N 7
H 5
D I S S .
S U S T R U T T U R A
J 1
P A N D U I T 1 0 0 - 5
1 2 3 4 5
J 3
P A N D U I T 1 0 0 - 1 2
1 2 3 4 5 6 7 8 9 1 0 1
1 1 2
J P 2
J U M P E R
J P 1
J U M P E R
S W 1
S W I T C H 1 0 2
R 4 5
1 2 0 K
R 4 2
4 7 K R V 2 0 C M
R 4 4
4 7 0 R V 2 0 C M
R 4 3
P O T 1 0 K P I H E R P C 1 6
J 2
C O N N E T T O R E S C H E D A C O N T R O L L O
1 2 3 4 5 6 7 8 9 1 0
1 1
1 2
1 3
1 4
1 5
1 6
1 7
1 8
1 9
2 0
2 1
2 2
2 3
2 4
2 5
2 6
2 7
F A S T O N M
C N 2
F A S T O N M
C N 1
H 9
E L B O M E C M L 7 3 / 3 8
H 7
E L B O M E C M L 7 3
/ 3 8
R 4 6
1 K 0 . 5 W
R 4 9
2 K 2
R 4 8
1 0 K
C 4 2
1 0 n
Q 1 0
B C 3 3 7
D 2 6
L E D G I A L L O
L 1
I N D U
C T O R C O U P L E D
R 5 0
1 M 0 . 5
W
R 5 1
1 0 R
F A S T O N M
C N 1 1
F A S T O N M
C N 9
F A S T O N M
C N 3
F A S T O N M
C N 2
F A S T O N M
C N 7 A
F A S T O N M
C N 8 F
A S T O N M
C N 1 0
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8
Driver wiring diagram
D R -
D R +
A L H +
A L H -
A L L +
A L L -
D R H +
D R H -
D R L +
D R L -
2
5
3
6 7 8
2 3
5 6 7 8
D 1
1 8 V
D 2
1 8 V
D 3
1 0 V
R 6
1 K
R 1
4 R 7
R 4
2 K 2
R 2
3 K 9
C 1
4 7 0 p C E R P 5
C 2
. 1 u
Q 1
B C 3 3 7
Q 2
B C 3 2 7
C 3
2 . 2 u 2 5 V
T A N T .
R 8
3 K 9
C 4
4 7 0 p C E R P 5
R 3
2 2 0
R 5
2 R 2
D 4
1 8 V
D 5
1 8 V
D 6
1 0 V
R 1 1
1 K
R
7
4 R 7
R 9
2 K 2
C 5
. 1 u
Q 3
B C 3 3 7
Q 4
B C 3 2 7
C 6
2 . 2 u 2 5 V T A N T .
R 1 0
2 R
2
I S O 4
H C P L 3 1 0 1
I S O 5
H C P L 3 1 0 1
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Switching auxiliary power supply unit wiring diagram
9
R 2 8 o n
l y v e r s
i o n
1 4 5
V B U S +
V B U S -
R E L +
R E L -
A L H +
A L H -
A L L +
A L L -
A L P 1 2
A L 0
A L M 1 2
A L P 5
P P R +
S O L O P E R L O G I C A O M I C R O
O V L O
U V L O
1 2
4 5 6
N O N M O N T A T O S U M M A
R 2 8 : M O N T A R E S O
L O S U 1 1 4 1 8 5 ( 1 4 5 )
P R I M A R I O
S E C O N D A R I O
I S O
L A M E N T O 3 7 5 0 V
C A P S U L A S E C
O N D A R I O
D 7
B Y V 2 7 - 2 0 0
D 1 2
B Y V 2 7 - 2 0 0
C 7
1 0 u 5 0 V
C 1 5
4 7 0 u 2 5 V
C 1 6
4 . 7 u 2 5 V
C 1 7
. 1 u
N D 1
2 3 N
S +
1 3
D 8
B Y V 2 7 - 2 0 0
C 9
1 0 u 5 0 V
N D 2
2 3
D 1 3
B Y V 2 7 - 2 0 0
C 2 1
4 7 u 2 5 V
C 2 2
4 . 7 u 2 5 V
C 2 3
. 1 u
N S -
1 3
N S B
7
C 2 6
4 7 0 u 2 5 V
D 1 6
B Y V 2 7 - 2 0 0
U 4
L M 7 8 0 5 C T
I N
1
O U T
3
G N D
2
C 2 8
. 1 u
C 2 9
. 1 u
C 2 7
1 0 u 5 0 V
D 1 5
1 N 4 0 0 4
R 1 6
2 2 R
R 1 8
1 K
R 2 5
1 R 2
D 1 1
1 8 V
N P
8 8
D 9
B A 1 5 9
R 1 4
1 0 K 5 W F
C 1 1
4 . 7 n 6 3 0 V M K P P 1 0
C 1 9
4 7 0 p C E R P 5
R 2 1
1 K
R 2
4
4 3 K 1 %
R 2 2
4 K 7
C 2 0
1 n 6 3 V p 5
C 1 8
. 1 u
R 1 9
1 5 0 K C
1 4
4 7 0 p C E R
P 5
C 1 3
4 7 n
R 1 7
4 . 3
K 1 %
R 2 0
4 7 K R
1 5
2 2 K 1 %
D 1 4
B Y V 2 7 - 2 0 0
C 2 4
2 2 u 2 5 V
N A
1 3
D 1 0
1 N 4 1
4 8
C 1
0
1 0 0 u 5
0 V
C 1 2
. 1 u U
5 A
L M 3 9 3
+ -
3 2
1
8 4
U 5 B
L M 3 9 3
+ -
5 6
7
8 4
R 2 9
1 K 5
R 3 3
2 7 K 1 %
R 3 2
1 5 K 1 %
R 3 1
1 K 1 %
R 3 0
2 2 K 1 %
C 3 0
1 u M K T P 5
R 2 7
2 7 0 K 0 . 5
W
R 2 6
2 2 0 K 0 . 5
W
C 8
. 2 2 u 6 3 0 V M K P
P 2 7 . 5
C 2 5
. 1 u
I S O 3
C N Y 1 7
H 3
E L B O M E C M L 2 6 A A
H 1
E L B
O M E C M L 2 6 A A
U 2
L M 7 8 1 2 C T
I N
1
O U T
3
G N D
2
U 3
L M 7 9 1 2 C T
I N
2
O U T
3
G N D
1
Q 5
I R F B E 3 0
R 2 8
3 9 0 R
H 2
E L B O M E C M L 2 6 A A
R 1 2
4 7 K 0 . 5
W
R 1 3
4 7 K 0 . 5
W
U 1
U C 3 8 4 2 A N
V F B
2
I S E N
3
R T / C T
4
V R E F
8
C O M P
1
O U T
6
V C C
7
G N D
5
J P 3
J U M P E
R
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T h e s a m e
f o r a
l l v e r s
i o n s
SMD module wiring diagram
+ V C
C
- V C C
+ V C C
+ V C C
+ V C C
+ V C C
- V C C
+ V C C
+ V C C
+ V C C
+ V C
C
+ V C C
- V C C
- V C C
+ V C C
F R E Q
P O T
C O R R .
C O M P . C
O R T O
C O M P .
S T A R T
A M P L I F .
E R R O R E
H O T S T A R T
A R C F O R C E
S P E G N I M E N T O
C C
A L L A R M E
A M P L I
S H U N T
T E R M I C O
P R O T .
P R I M A R I O
L I M I T .
D U T Y
I P L I M 1
+ 5
D R +
O U T -
+ 5
+ 5
+ 5
C C
O U T +
S H +
T M A X 1
T M A X 2
T M A X 2
I O U T
P O T
F U N Z
T H +
T H -
P P R +
B L A K
I P L I M 2
T A +
T A -
V O U T
V O U T S
T A R T
C C
S T A R T
S T A R T
I O U T
O U T -
S H +
T H +
T H -
P P R +
A L P 5
A L M 1 2
A L P 1 2
O U T +
A L 0
O U T +
T A +
T A -
B L A K
P O T
T M A X 1
R I F
D R -
D R +
F U N Z
C C
I O U T
I P L I M 2
I P L I M 1
T M A X 2
+ 5
V O U T
R I F
R 1
1 K
R 2
3 9 R
D 1
1 N 4 1 4 8
D 2
1 N 4 1 4 8
D 3
9 V 1
R 7
2 2 0 R
R 1 1
2 2 K
R 4 2
2 K
R 2 1
1 K
R 1 7
6 K 8
C 2
. 1 u C E R
C 3 4 n
7 N P O
Q 1
B C 3 3 7
R 5 4
7 K R V 2 0 C M
C 1
. 1 u C E R
R 4 9
1 0 0 K
R 5 2
8 2 K
R 5 0
1 5 K
R 4 3
2 2 K
C 2 1
1 0 n
C 1 7
. 1 u C E
R
C 2 3
. 1 u C E R
D 1 8
1 5 V
D 1 7
1 5 V
U 1 D
L M 3 2 4 D
+ -
1 2
1 3
1 4
4 1 1
R 5 4
3 K 3
R 5 3
2 K 2
R 4 4
5 K 1
C 2 0
. 1 u C E R
R 4 7
1 5 0 K
R 5 1
4 7 K
R 4 6
3 K 3
D 1 6
1 N 4 1 4 8
C 2 2
2 2 u 1 6 V
R 4 0
1 K
R 4 1
1 0
0 R
R 3 6
1 2 K
C 1 1
1 0 0 p C E R
C 1 5
. 1 u C
E R
C 1 8
. 1 u C E R
U 4
L M 3 0 8 D
+ -
3 2
6
7
1
4
8
U 1 A
L M 3 2 4 D
+ -
3 2
1
4 1 1
R 9
2 2 K
R 3
4 K 7
R 8
4 K 7
C 5
4 n 7
U 1 B
L M 3 2 4 D
+ -
5 6
7
4 1 1
R 1 0
1 0 0 K
C 6
. 1 u C E R
R 1 3
2 K 2
R 3 0
2 K 2
C 1 4
1 0 u 1 6 V
D 1 1
1 N 4 1 4 8
R 3 4
2 2 K
U 1 C
L M 3 2 4 D
+ -
1 0 9
8
4 1 1
R 2 5
1 0 K
R 2 4
6 K 8
R 3 8
3 K 3
R 4 8
3 K 3
D 1 3
1 N 4 1 4 8
D 1 2
1 N 4 1 4 8
D 4
1 N 4 1 4 8
R 1 5
1 5 0
R 2 3
1 0 K
R 1 2
3 3 K
D 5 1 N
4 1 4 8
R 2 8
1 2 0 K
R 3 5
1 5 K
C 1 2
1 n C E R
Q 6
B S 1 7 0
D 1 4
1 N 4 1 4 8
C 1 9
1 0 n
R 3 1
2 K 2
R 1 4
2 K 2
Q 7
B C 3 3 7
R 3 7
3 K 3
C 9
1 0 u 1 6 V
D 7
1 N 4 1 4 8
R 1 8
1 8 0 K
Q 2
B S 1 7 0
Q 3
B C 3 3 7
R 2 2
3 K 3
D 9
1 N 4 1 4 8
R 3 9
1 0 K
R 2 6
1 0 K
D 6
1 N 4 1 4 8
R 1 6
4 7 K
D 1 5
1 N 4 0 0 4
R 4 5
3 3 0 R
C 7
1 n C E R
D 1 0
1 N 4 1 4 8
C 1 3
. 2 2 u
R 3 3
4 K 7
Q 5
B C 3 3 7
R 3 2
1 K
R 1 9
4 K 7
J 2
S T R I P S I L P R O N E R C O M A T E L
1 2 3 4 5 6 7 8 9 1 0
1 1
1 2
1 3
1 4
1 5
1 6
1 7
1 8
1 9
2 0
2 1
2 2
2 3
2 4
2 5
2 6
2 7
R 6
4 K 7
C 8
1 n C E R
C 4
1 n C E R
C 1 6
1 n C E R
U 3
A
L M
3 3 9 D
+ -
7 6
1
3 1 2
U 3 B
L M 3 3 9 D
+ -
5 4
2
3 1 2
U 3 C
L M 3 3 9 D
+ -
9 8
1 4
3 1 2
U 3 D
L M 3 3 9 D
+ -
1 1
1 0
1 3
3 1 2
U 2
U C 3 8 4 5 A D 8
V F B
2
I S E N
3
R T / C T
4
V R E F
8
C O M P
1
O U T
6
V C C
7
G N D
5
C 2 4
2 2 p
R 5 8
1 K
R 5 5
3 9 R
R 5 6
3 9 R
R 5 7
3 9 R
C 2 6
2 2 n
C 2 5
1 0 0 p C E R
D 1 9
B A T 4 2
TECHNOLOGY 145-165-200
8/9/2019 Telwin Technika 145 165 200 B
11/12
11
D 2
, D 3 o n
l y
v e r s
i o n
1 6 5 -
2 0 0
Secondary circuit board wiring diagram
X F
S +
X F
S -
O U T +
S H +
R 4
1 0 R 5 W F
C 2
1 n 5 6 3 0 V M K P K P
1 5
D 1
D 3
D 4
D 5
R U R U 8 0 6 0
D 2
R U R U 8 0 6 0
R 2
S H U N T 1 . 1 m
O h m
H 1
H E A T S I N K
I N S E R T O
J 2
I N S E R T O
J 4
F A S T O N
J 1
I N S E R
T O
J 3
TECHNOLOGY 145-165-200
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SINCERTACCREDITAMENTO ORGANISMICERTIFICAZIONE
SISTEMAQUALITA'CERTIFICATO
U N I E N I S O 9 0 0 1 TGA-ZQ-002/92-00
DeutscherAkkreditierungsRat
CERTIFIED QUALITY SYSTEM
ISO
9001
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