inver ter

“ r e p a r a t i o n n o - p r o b l e m ”

Cod.988367

CONTENTS PAGE

OPERATION AND ELECTRICAL DIAGRAMS................... 2- Block diagram 2- Analysis of block diagram 3- Illustrations 5- Electrical diagrams 7

REPAIR GUIDE.................................................................. 11- Equipment required 11- General repair instructions 12- Troubleshooting and remedies 12- Testing the machine 15- Illustrations 17

SPARE PARTS LIST.......................................................... 21

REPAIR SHEET................................................................. 23

TROUBLESHOOTING

AND REPAIR MANUAL

TROUBLESHOOTING

AND REPAIR MANUAL

TROUBLESHOOTING

AND REPAIR MANUAL

TROUBLESHOOTING

AND REPAIR MANUAL

30/06/02

SUPERIOR 240 CE

2

BLOCK DIAGRAM

OPERATION AND WIRING DIAGRAMSOPERATION AND WIRING DIAGRAMSOPERATION AND WIRING DIAGRAMSOPERATION AND WIRING DIAGRAMS

SUPERIOR 240 CE

1927

1426

12

34

56

78

910

11

FAN

MA

X.

CU

RR

ENT

LIM

ITE

R

+ -

25

SH

UN

TA

MP

LIFI

ER

1516

17

18

32

MM

A TIG-

LIFT

HO

T S

TAR

T

AR

C F

OR

CE

2021

3635

1213

242223

34

29 30 31

33

27 28

+-

MA

INS

IN

PU

TE

MC

FIL

TE

R

VA

RIS

TO

RP

RE

-CH

AR

GE

RE

CT

IFIE

RFI

LTE

R C

HO

PP

ER

PR

.CU

RR

EN

TT

RA

NS

FOR

ME

RS

EC

. D

IOD

ES

ND

UC

TAN

CE

SE

C.E

MC

OU

TP

UT

BR

IDG

EC

ON

TR

OL

SH

UN

TFI

LTE

R

UN

DE

RV

OLT

AG

ES

AFE

GU

AR

DO

VER

VO

LTA

GE

SA

FEG

UA

RD

PO

WER

SU

PP

LYLE

D

FLY

BA

CK

PO

WE

RD

RIV

ERC

UR

REN

T R

EA

DER

SU

PP

LY A

ND

LIM

ITE

R P

R.

PH

AS

E FA

ILU

RE

FUN

CTI

ON

SE

LEC

TOR

AU

XIL

IAR

YP

OW

ER

SU

PP

LY

SH

OR

T C

IRC

UIT

DET

ECTO

R

AL

AR

M B

LOC

K

AD

DER

DU

TY

CY

CL

EM

AK

ER

DIO

DE

TH

ERM

OS

TAT

SEC

.

PO

WER

TRA

NS

FOR

MER

THE

RM

OS

TAT

ALA

RM

LED

C

UR

RE

NT

PO

TEN

TIO

ME

TER

SH

OR

TC

IRC

UIT

DEL

AY

HO

T-S

TAR

TA

RC

-FO

RC

EP

OT

ENT

IOM

ETER

DU

TY C

YC

LELI

MIT

ER

SUPERIOR 240 CE

Block 9ANALYSIS OF THE BLOCK DIAGRAMSecondary diodes NOTE: Unless indicated otherwise, it should be assumed Consisting of: D1, D2, D3, D4, D5 (secondary board)that the components are assembled on the primary N.B. Some versions may have 4 power diodes (D1, D2, D3, board or machine.D4)D1 and D2 make the current circulating in the transformer Block 1one-way, thus preventing saturation of the nucleus.EMC Filter D3, D4 and D5 recirculate the inductance output current Consisting of: C1, C2, C3, C4, C5, C6, C7, L1, L2, L3 (input when the IGBT’s are not conducting, by-passing the filter board)transformer.Prevents noise from the machine from being transmitted

along the main power line and vice versa.Block 10

Inductance and shuntBlock 2Consisting of: L1, R1 VaristorThe inductance levels the secondary board diodes’ output Consisting of: RV1, RV2, RV3 (input filter board)current making it practically continuous/direct. The shunt Prevents spike noise from the mains, with amplitude reads the current circulating in the inductance and sends it greater than 400V, from entering the machine.to block 24/25 (amplifier shunt), which will process the data.Block 3

Pre-chargeBlock 11Consisting of: K1, K2, R3, R9

Secondary EMC FilterPrevents the formation of high transitory currents that could Consisting of: C1, C2damage the main power switch, the rectifier bridge and the Prevents noise from the power source from being electrolytic capacitors.transmitted through the welding cables and vice versa.When the power source is switched on relays K1 and K2

are de-energised, capacitors C6, C17, C22, C38, C45, C47 Block 12are then charged by R3 and R9. When the capacitors are

Flyback power supplycharged the relays will be energised.Consisting of: U4, Q6, T3, U1, U2, U3Uses switching methods to transform and stabilise the Block 4voltage obtained from block 5 (filter) and supply 2 voltage Rectifier bridgevalues of 27V that enable block 13 (driver) to be powered Consisting of: D19, D10correctly. It also generates a further three stabilized Converts the mains alternating voltage into continuous voltages (U1, U2, U3) of -12V, +5V and +12V which are pulsed voltage.mainly used to power the control board. Block 5

Block 13FilterDriverConsisting of: C6, C17, C22, C38, C45, C47Consisting of: U1 (opto-insulators board), Q7, Q8 and U2 Converts the pulsed voltage from the rectifier bridge into (opto-insulators board), Q9, Q10.continuous voltage.Takes the signal from block 12 (flyback power supply) and, controlled by block 15 (duty cycle maker), makes the signal Block 6suitable for piloting block 6 (chopper).Chopper

Consisting of: Q3, Q4, Q5, Q12, Q13, Q14Block 14Converts the continuous voltage from the filter into a high

Primary current reader and limiterfrequency square wave (32.5 kHz approx.) capable of Consisting of: D1, R2, R55, R56, R57 R68 (control board)piloting the power transformer.Picks up and limits the signal from block 7 (current Regulates the power according to the required welding transformer) and using R68 limits the maximum admissible current/voltage.primary current. This signal is also scaled down so that it can be processed and compared in block 15.Block 7

Current transformerBlock 15Consisting of: T1

Duty cycle makerThe C.T. is used to measure the current circulating in the Consisting of: U2=UC3845 (control board) power transformer primary and transmit the information to Processes the information from block 16 (adder) and block block 14 (primary current reader and limiter).14 (primary current reader and limiter) and produces a square wave with variable duty cycle limiting the primary Block 8current to a maximum pre-set value under all Power transformercircumstances.Consisting of: T1

Adjusts the voltage and current to values required for the Block 16welding procedure,

Adderalso forming galvanic separation of primary from Consisting of: U1A, U1B (control board)secondary (welding circuit from the power supply line).Processes the information from blocks 18, 25, 27, 28 and

3

SUPERIOR 240 CE

sends it to block 15 (duty cycle maker). (control board).If one of the three input phases is lost this alarm cuts in.

Block 17Alarm Block Block 25Consisting of: Q1, D12, D13, R80, Q12 (control board) Shunt AmplifierWhen an alarm is detected, the output current is cut off by Consisting of: U4 (control board)operating directly on block 15 (duty cycle maker) in the Amplifies the signal from block 10 (inductance shunt) and event of: makes it appropriate for block 26 (maximum current 1) Triggering of thermostatic capsule on secondary board limiter).

dissipator diodes.2) Triggering of thermostatic capsule on power Block 26

transformer. Maximum current limiter3) Triggering due to undervoltage. Consisting of: R62 (control board)4) Triggering due to overvoltage. Processes the information from block 25 (shunt amplifier) 5) Phase loss at input. and, using R62, regulates the maximum welding current to 6) Short circuit at output (electrode holder clamp and earth be supplied by the power source.

cable connected to each other or electrode stuck to This signal is scaled down so that it can be processed and piece being welded). compared in l block 16 (adder).

Block 18 Block 27Potentiometer Function selectorConsisting of: R72 (control board) Consisting of: S1Used to set the reference voltage needed to adjust the Uses the switch to select the type of welding process: MMA output current: changes the current from the minimum to OR TIG-LIFT.the maximum value.

Block 28 Block 19 Short circuit detector

Yellow LED alarm light Consisting of: U3B (control board)Consisting of: D35 (control board) If the welding voltage P is lower than 10V this circuit causes It is switched on by block 17 (Alarm Block) if an alarm block 30 to trigger (arc force)occurs.

Block 29 Block 20 Hot Start

Overvoltage safeguard Consisting of: U3D, Q3, C9, Q2 (control board)Consisting of: U5A, R38, R40 When welding starts this block generates a temporary If the main supply voltage exceeds the maximum value this overcurrent, which can be adjusted by R72 and is used to safeguard triggers (a tolerance of approx. ±15% of the pre-heat the electrode in MMA.power supply voltage is allowed: outside this range the safeguard triggers). Block 30

Arc ForceBlock 21 Consisting of: Q7, C14, Q6 (control board)

Undervoltage safeguard If the arc voltage falls below 10V, this block produces a Consisting of: U5B, R30, R32 temporary increase in output current, which is used to If the main supply voltage falls below the minimum allowed detach the electrode from the piece after sticking has value this safeguard triggers (a tolerance of approx. ±15% occurred.of the power supply voltage is allowed: outside this range the safeguard triggers). Block 31

Short circuit delayBlock 22 Consisting of: U3A (control board)

Secondary diodes thermostat If output shorting persists, this block switches off the power Consisting of: thermostatic capsule ST1 source by means of block 17 (alarm block).When the temperature of the secondary board dissipator reaches 70°C (approx.) this safeguard triggers. Reset is Block 32 automatic when the cause for alarm is removed. Hot-Start/Arc-Force Potentiometer

Consisting of: R77 (control board)Block 23 Used to set the reference voltage required to adjust the

Power transformer thermostat strike current percentage (0-100%) (Hot-Start) and the Consisting of: thermostatic capsule ST2 antistick overcurrent (Arc-Force).When the temperature of the power transformer is too high this safeguard triggers. Reset is automatic when the cause Block 33for alarm is removed. Auxiliary Power Supply

Consisting of: R111, R45, D15 (control board)Block 24 This block reserves a voltage (about 11Vdc) for the

Phase loss shorting detection circuit so as to detect the shorting at Consisting of: ISO2, ISO3 opto insulators board, U5C output, if the power is disabled.

4

SUPERIOR 240 CE

Block 34 Block 36 Duty Cycle Limiter FanConsisting of: U3C (control board) Consisting of: V1 and V2Limits the machine duty cycle under loadless operation. Used to cool the power components and is powered by

block 12 (at 12Vdc).Block 35

Power supply LED Consisting of: green LED D8 (control board)Indicates when the machine is correctly powered and ready to weld.

Input filter board(1) EMC FILTER

(2)VARISTOR

(6) CHOPPER(7) CURRENT

TRANSFORMER

(5)FILTER

(6)CHOPPER

(13)DRIVER OPTO

ISOLATOR(U1,U2, ISO2, ISO3)

Primary board

ILLUSTRATIONS

(4) PRECHARGE

(3) RECTIFIERBRIDGE

(12) FLYBACKPOWER SUPPLY

(1) EMC FILTER

5

SUPERIOR 240 CE

Control board

Scheda secondario

(9) DIODESECONDARY

(16)RADER

(18)POTENTIOMETER

CURRENT

(35)POWER SUPPLY GREEN LED

(19)YELLOW LED ALARM LIGHT

(27)FUNCTIONSELECTOR

(26)MAXIMUM

CURRENT LIMITER

(15) DUTY CYCLE MAKER(14) PRIMARY CURRENTREADER AND LIMITER

(32)POTENTIOMETER

HOT-START / ARC-FORCE

Secondary board

(22) SECONDARYDIODE THERMOSTAT

(9) DIODESECONDARY

6

SUPERIOR 240 CE

General wiring diagram

WIRING DIAGRAM

7

SUPERIOR 240 CE

Wiring diagram primary board - power

Wiring diagram primary board - driver

8

Wiring diagraminput filter board

9

Wiring diagram primary board - power supply

Wiring diagram secondary board

SUPERIOR 240 CE

10

Wiring diagram control board

Wiring diagram control board

SUPERIOR 240 CE

4

2

7

1

3

9 8

6 5

ESSENTIAL INSTRUMENTS1 Dual trace oscilloscope 802401 (*)

2 Static load generator 802110 (*)

3 Variac 0 - 500v 4500VA 802440 (*)

4 Digital multimeter

5 Hall probe 802406 (*)

6 HV Power Supply 802403 (*)

USEFUL INSTRUMENTS7 Unsoldering station

MISCELLANEOUS8 Flat jaw pincers

9 Cutting nippers

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

SUPERIOR 240 CE

EQUIPMENT REQUIRED

REPAIR GUIDEREPAIR GUIDEREPAIR GUIDEREPAIR GUIDE

11

working surfaces etc.).HV POWER SUPPLY MODULE B) To ensure the heat flow between the electronic components and the dissipator, always place a thin layer of thermo-conductive grease

THE HV POWER SUPPLY is used to ensure operation of the switching (e.g. COMPOUND GREASIL MS12) between the contact zones.power supply (the circuit on the primary board supplying auxiliary C) The power resistors (should they require replacement) should voltages), even when the machine is operating at low voltage. always be soldered at least 3 mm above the board.It can be easily assembled by referring to the electrical diagrams in D) If silicone is removed from some points on the boards, it should be figure A and using the following components: re-applied. N.B. Use only non-conducting neutral or oximic

reticulating silicones (e.g. DOW CORNING 7093). Otherwise, T1 = insulation transformer 230-230V 50VA(*) silicone that is placed in contact with points at different potential D1 = rectifier bridge 36MB 80 (cod. 112357) (IGBT rheophores etc.) should be left to reticulate before the C1 = electrolytic capacitor 470uF 400V ALL machine is tested. (cod.112514) E) When the semi-conductor devices are soldered the maximum R1 = resistor 10 ohm 5W 5% temperature limits should be respected (normally 300°C for no R2 = resistor 100K ohm 2W 5% more than 10 seconds).F1 = delayed action fuse 1.5 A Fuse holder 5X20mm F) It is essential to take the greatest care at each disassembly and Female red and black faston assembly stage for the various machine parts.Plastic box. G) Take care to keep the small parts and other pieces that are

dismantled from the machine so as to be able to position them in the reverse order when re-assembling. (Damaged parts should never be left out but should be replaced, referring to the spare parts list given at the end of this manual).ELECTRICAL DIAGRAM FOR POWER SUPPLY (HV OUTPUT):

H) The boards (repaired when necessary) and the wiring should never be modified without prior authorisation from Telwin.

I) For further information on the specifications and operation of the machine, refer to the Instruction Manual.

J) WARNING! When the machine is in operation there are dangerously high voltages on its internal parts so do not touch the boards when the machine is live.

THE INSULATION TRANSFORMER CAN BE REPLACED WITH TWO TRANSFORMERS OF THE SAME POWER, CONNECTING THE SECONDARIES ACCORDING TO THE FOLLOWING DIAGRAM:

1) Disassembling the machineEvery operation should be carried out in complete safety with the power supply cable disconnected from the mains outlet.A) Undo the 8 screws fastening the 2 plastic covers (4 each) to the front

and back (figure 1A).B) Undo the 8 screws fastening the top cover to the structure (figure

1B).C) Slide out the top cover by pulling gently outwards (figure 1B).

NOTE: To test the machine at low voltage special testing wiring should D) Separate the base from the upper metallic structure by removing the also be used so as to be able to force a number of alarm signals 4 screws fastening the one to the other and disconnecting (from the between the primary and control boards. primary board) the 3 fastons R,S,T (J3,J4,J5) connecting the main This wiring is supplied with the HV power supply (or it can be obtained power supply switch (figures 2A and 2B).on request from Telwin: wiring KIT code 902760), or it can be easily E) Slide out the whole upper assembly (the structure anchoring the assembled referring to the electrical diagram in figure B: various boards) by rotating gently upwards from the back and place

it on the work bench (figure 3).F) Place the assembled base near the upper assembly and reconnect

the 3 fastons R,S,T so that the machine is able to operate (figure 4).

After completing the repairs, proceed in reverse order to re-assemble the machine and fasten down the top cover and plastic covers.

2) Cleaning the inside of the machineUsing compressed air, carefully clean the components of the power

Connector to be Connector to be source since dirt is a danger to parts subject to high voltages and can fitted into fitted intocontrol card primary card damage the galvanic separation between the primary and secondary

boards. It is important to take special care when cleaning the following parts:Air extraction fan attached to front (figure 2A):check whether dirt has damaged the correct rotation of the blades, if there is still damage after cleaning replace the fan.

Air inlet fan attached to back (figure 2B):check whether dirt has damaged the correct rotation of the blades, if there is still damage after cleaning replace the fan.GENERAL REPAIR INSTRUCTIONSPrimary board (figure 3):The following is a list of practical rules which must be strictly adhered to A) Rheophores of IGBT's Q3, Q4, Q5, Q12, Q13, Q14.if repairs are to be carried out correctly.B) Rheophores of recirculating diodes D7, D24.A) When handling the active electronic components, the IGBT's and C) Rheophores of snubber network diodes D4, D27.Power DIODES in particular, take elementary antistatic D) Black box connection zone (it contains the board to which the driver precautions (use antistatic footwear and wrist straps, antistatic

T R O U B L E S H O O T I N G A N D REMEDIES

10 5

F1 R1

R2

D1

T1

Figure A

Figure B

1 2 3 4 5 6

20.20 mm

SUPERIOR 240 CE

12

circuit opto-insulators are attached). 4) Checking power and signal wiringIt is important to check that all the connections are in good condition

Secondary board (figure 6): and the connectors are inserted and/or attached correctly.A) Power diodes D1, D2, D3, D4, D5. To do this, take the cables between finger and thumb (as near as

possible to the fastons or the connectors) and pull gently outwards: the B) Thermostatic capsule on the dissipator cables should not come out of the fastons or connectors.C) Shunt R1

Power transformer and inductance assembly (if the primary board has to be removed, otherwise it can be cleaned superficially from the secondary board side).

In particular on the primary board (figure 3) it is necessar y to check:A) The connections R,S,T (J3, J4, J5) of the 3 phases to the main

switch and upstream of the switch: input filter and power supply cable.

B) The 2 connections between the primary board and the power transformer (PIN1TRAFO and PIN2TRAFO).

3) Visual examination of the machine C) The power supply connections for the 2 fans to J9, J10, J11, J12).Make sure there is no mechanical deformation, dent, or damaged and/or disconnected connector. In particular on the secondary board (figure 6) the following checks Make sure the power supply cable has not been damaged or should be made:disconnected internally and that the fans work correctly with the A) Connections between the power transformer and the 2 secondary machine switched on. Make a visual check of components listed below board bushes.for signs of burning or breakage: B) Correct connection for the output equalisation inductance (between A) Main power supply switch (figure 2B) the secondary board bush and machine outlet OUT-).

Use the multimeter to check whether the contacts are stuck together C) Connections to the shunt (secondary dissipator, shunt reader and or open. shunt e positive machine outlet OUT+).Probable cause: D) The wiring between the thermostatic capsules on the secondary Mechanical or electrical shock (e.g. bridge rectifier or IGBT in short dissipator and the power transformer (connected in series).circuit, handling under load).

B) Current potentiometer R72 (figure 2A)Probable cause: 5) Electrical measurements with the machine mechanical shock. switched off

C) Welding mode selector switch S1 (figure 2A)With the digital multimeter set for diode testing check the following

Probable cause:components (junction voltages not less than 0.2V):

mechanical shock.A) Rectifier bridges D10, D19 (figure 5).

D) Input filter board varistors (figure 4)B) IGBT's Q3, Q4, Q5, Q12, Q13, Q14 (absence of shor t circuits

Probable cause:between collector-gate and between collector-emitter figure 5).

power supply voltage much higher than 400Vac.C) Diodes D1, D2, D3, D4, D5 on secondary board between anode

E) Relays K1, K2 primary board (figure 5)and cathode (figure 6).

Probable cause: See main power supply switchN.B. If the relay contacts are stuck together or dirty, do not attempt to

With the digital multimeter set on ohms check the following detach them and clean them but replace the relay.

components:F) Electrolytic capacitors C6, C17, C38, C45 primary board

A) Resistors R3, R9: 47 ohm ±5% 7W (precharge figure 5).(figure 5)

B) Resistors R1, R2, R69, R71: 10 ohm ±10% 11W (primary snubber Probable cause:

figure 5).- mechanical shock

C) Resistor R1: 10 ohm ±10% 5W (secondary snubber figure 6).- machine connected to a much higher line voltage than 400Vac,

D) Continuity test of the thermostatic capsules on the power - broken rheophore on one or more capacitor: the remainder will be

transformer and secondary board dissipator: disconnect the overstressed and become damaged by overheating,

fastons and - aging after a considerable number of working hours,

measure the resistance over their ends, it should be about 0 ohm - overheating caused by thermostatic capsule operational failure

(figure 6).G) IGBT's Q3, Q4, Q5, Q12, Q13, Q14 (figure 5)

Probable cause:- discontinuation in snubber network,

6) Electrical measurements with the machine - fault in driver circuit ,- poorly functioning thermal contact between IGBT and dissipator in operation(e.g. loosened attachment screws: check), The tests described below can be used to check the workings of the - excessive overheating related to faulty operation. power and control parts of the machine.

H) Primary board diodes D4, D7, D24, D27 (figure 5)Probable cause: Preparation for testing.excessive overheating related to faulty operation. A) Disconnect the fastons PIN1TRAFO (J8) and PIN2TRAFO (J2) of

I) Secondary board diodes D1,D2,D3,D4,D5 (figure 6) the power transformer from the primary board (figure 4).Probable cause: B) Set up the oscilloscope with the voltage probe x100 connected - discontinuation in snubber network, between the collector of Q6 (probe) and capacitor C47 from the Q3 - poorly functioning thermal contact between diodes and dissipator side (earth) on the primary board (figure 5).(e.g. loosened attachment screws: check),

C) On the primary board disconnect the jumper JP2.- faulty connection at machine outlet.

D) Connect the HV outlet of the HV power supply to the primary board as follows (figure 5):

(+) Positive ( clamp) to the PIN of connector JP2 from the resistor R75 side,

(-) Negative (faston) to the negative faston of the diode bridge D19.E) Disconnect the wiring connected to the control board and remove

K) Power transformer and filter inductance the control board (following the instructions given below).F) Connect the power supply cable of the machine to a 3-phase variac

with variable output 0-500 Vac.

N.B. Some versions may have 4 power diodes (D1, D2, D3, D4)

A) The wiring (J3) towards the primary board (J1).B) The wiring (J4) towards the remote control socket (CAD)C) The wiring (J1) to the thermostatic capsules, shunts and out-.

Parts fastened to the base (figure 4)If the primary and secondary boards are removed (with the diaphragm), clean the input filter carefully.

(so that the thermostats are connected in series)

J) Secondary board shunt R1 (figure 4)Check whether it has changed colourProbable cause:Overheating due to loosening of the screws connecting the shunts to the secondary circuits.

After gaining access to the components on the base:L) Input filter board varistors RV1, RV2, RV3 (figure 4)

Probable cause: power supply voltage much higher than 400Va

SUPERIOR 240 CE

13

Recommended tests. increase the voltage generated by the variac up to 24Vac.A) Switch on the HV power supply (HV output) and check that the H) Set up the oscilloscope with the probe x10 connected between the

precharge relays K1 and K2 on the primary board close with a slight gate (prod) and emitter (earth) of the IGBT Q3 on the primary board delay (figure 5). (figure 5). Check that the wave form on the display resembles that in

B) Use the oscilloscope to check that the voltage waveform between figure E. the collector of Q6 (probe) and rheofore of C47 from the Q3 side (earth) resembles that shown in figure C.

- repeat this test on Q12 on the primary board.I) Switch off the machine and the HV power supply. Also:

- disconnect the HV from the machine,C) On the primary board check the following power supply voltages: - reset the jumper JP2 on the primary board,

- between the cathode of D20 and the anode of D21 equal to +28V - replace the test wiring between the primary and control boards with ±5%, the original.- between the cathode of D12 and the anode of D13 equal to +28V J) Switch the machine back on and make sure that it is in alarm status ±5%, (yellow LED D35 lit up on the panel). Increase the variac voltage to - between the anode of D11 and case of U3 equal to +12V±5%, 320Vac and make sure the machine is always in alarm status. - between the anode of D6 and case of U3 equal to +5V±5%, Continue to increase the variac voltage and check that between the - between the cathode of D5 and case of U3 equal to –12V±5%.

values of 330Vac and 460Vac (approx.) the machine leaves alarm B) Switch off the HV power supply, reposition the control board and

status.reconnect the wiring with the exception of that between the primary

Finally, bring the variac voltage to 470Vac and make sure the board (to J1) and the control board (to J3). This should be replaced

machine does not return to alarm status (never take the variac above with the special test wiring as in figure B (take care to position the value 475 Vac). Bring the variac immediately back down to correctly).400Vac and switch off the machine.E) Switch the HV back on and check that:

- the green power supply LED D8 lights up,- the machine is not in alarm status (yellow LED D35 switched off).

F) Set up the oscilloscope with the probe x10 connected between the 7) Repairing and replacing the boardsgate (prod) and emitter (earth) of the IGBT Q3 on the primary board If repairing the boards is complicated or impossible, they should be (figure 5) completely replaced. Each board is identified by a 6-digit code (printed Check that the wave form on the display resembles that in figure D. 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.Note: 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 continues after it has been replaced correctly, check the other machine components. Unless otherwise required by the procedure, never alter the board trimmers.

A) Removing the primary board (figure 3)- Disconnect all the wiring connected to the board and the cables that

are connected from the board to the fans and the power transformer.NB. The connections between the primary board and the power transformer should never be inverted when the new board is assembled.- Remove the control board by first removing the potentiometer knobs

on the front panel, disconnecting the wiring and releasing the board from the 4 plastic columns attaching it to the primary board.

- Undo the 4 screws fastening the primary board to the metallic structure.

- repeat this test on Q4, Q5, Q12, Q13, Q14 on the primary board. - Extract the board, rotating it gently upwards from the front panel side N.B. If the signal is not present and/or the machine is in alarm status (this operation is easier if the front panel plate is pulled gently (yellow LED lit up) there could be a fault in the control board (in which outwards).case we recommend its replacement) or in the IGBT driver circuit NB. For re-assembly proceed in the reverse order.(figure 5).

G) Switch off the HV reconnect the 2 fastons between the primary board Please read the procedure for replacing the IGBT's and/or rectifier and power transformer (J2 and J8). bridges carefully:Switch on the HV and the variac (initially set to the value 0V), switch Even if only one IGBT is damaged, always replace all 6.off the main power supply switch on the machine and gradually

Figure C

Figure D

Figure E

Amplitude tollerance: ÷10%Frequency: 32,5Khz ÷ 10%

Amplitude tollerance: ÷10%Frequency: 32,5Khz ÷ 10%

Amplitude tollerance: ÷10%Frequency: 32,5Khz ÷ 10%

SUPERIOR 240 CE

14

- On the board, removed from the machine, unscrew the 4 nuts TESTING THE MACHINE fastening the dissipators and the 8 screws fastening the IGBT’s and diode bridges (figure 5). The test should be carried out on the assembled machine before

- Disconnect the thermostat wiring from the connector JP1. closing it with the top cover. During the tests with the machine in - Before making the replacement check whether the components operation never commute the selectors or activate the noninductive

piloting the IGBT's are also damaged: load electromagnetic switch.- with the multimeter on ohms make sure there is no short circuit

between the 1st and 3rd bump contacts of the printed circuit Preparation for testing(between gate and emitter) for each component.

A) Using cables with suitable dinse sockets, connect the machine to the - alternatively, the resistors R17, R19, R24, R45, R46, R47 could

static load generatorhave burst and/or diodes D9, D14, D22 and D23 may be unable to

B) Connect a voltage probe x100 between the collector (prod) and function at the correct Zener voltage (this should have shown up in

emitter (earth) of Q5.the preliminary tests).

C) Pass the current probe of the Hall effect transducer along the cable - Unsolder the components, clean the solder from the bump contacts

connecting the power transformer to the faston PIN2TRAFO (J2) and separate the board components.

with the reference arrow entering J2.- Clean any irregularity or dirt from the dissipators. If the IGBT's have

D) Lastly, connect the Hall Probe and the voltage probe to the burst the dissipators may have been irreversibly damaged: in this

oscilloscope.case they should be replaced.

E) Disconnect the jumper JP2 on the primary board.- Apply thermoconductive grease following the general instructions.- Prepare the components for replacement. For the IGBT's, bend the

rheofores at 90° (never bend and/or place the parts under tension near the case).

- Position the components on the dissipator with the fastening screws, but do not tighten the screws completely

G) Disconnect the wiring connecting the control board (J3) and primary - Join the dissipator/component assembly to the printed board,

board (J1) and replace it with the special test wiring as in figure B (as inserting all the rheofores in the bump contacts and the threaded before).spacers on the 4 attachment holes.

H) - Attach the dissipators with the nuts and lock them once and for all in the following order:

I) Connect the machine power supply cable to the 3-phase variac with - the nuts fastening the dissipators to the printed circuit with a torque variable output 0-500 Vac.wrench setting of 2 Nm ±20%;

- the screws fastening the rectifiers to the dissipators with a torque Recommended tests.wrench setting of 2 Nm ±20%;A) No-load test:- the screws fastening the IGBT's to the dissipators with a torque - With the static load generator disconnected first switch on the HV wrench setting of 1 Nm ±20%.

power supply and make sure that after a brief pause (green LED D8 - Solder the terminals taking care not to let the solder run along them.and yellow LED D35 both lit up) the pre-charge relays K1 and K2 - On the component side cut away the protruding part of the rheofores (figure 5) commute and the fans start operating.and check they are not shorted (especially the gate and emitter).

- Switch on the machine and the variac and bring the latter to 400 Vac.- Check that the voltage and current wave forms displayed on the NOTE. The 6 IGBT's should belong to the same selection kit supplied by

oscilloscope resemble those in figure F.Telwin.

B) Removing the secondary board (figure 6). Unless the dissipator is damaged due to a destructive explosion of the diodes, in general it is not necessary to remove the secondary board and the diodes can be replaced directly on the board mounted on the machine. Anyway, if it is necessary to remove it, undo the 4 screws attaching it to the machine structure, remove the 3 hexagonal-head screws fastening the shunt and connecting the power transformer then, lastly, disconnect the thermostatic capsule wiring and make the replacement.

Please read the procedure for replacing the secondary board diodes carefully (figure 6): - Turn the machine upside down, undo the screws fastening the

damaged components to the dissipator and unsolder the metal tab.- Having removed the components, remove any dirt or irregularities

from the dissipator.- Apply thermoconductive grease following the general instructions.- Place the components on the dissipator coinciding with the soldering

areas and fasten them with the screws (torque wrench setting 1.4 Nm ±20%).

- Solder the tabs, taking care not to form short circuits with the solder.NOTE. Make sure that R1 and C1 (secondary snubber) are correctly soldered to the printed circuit

- Switch off the machine, the variac and the HV power supply.C) Control board - Disconnect the machine from the variac and the HV power supply.

If the fault is in the control board, we strongly advise its immediate - Reset the jumper JP2 and the original wiring between the primary replacement without further intervention. (J1) and control (J3) boards.

B) Minimum load test:- Set up the static load generator with the switch settings as in the table in figure G, position the welding current potentiometer on the

F) Connect the HV outlet of the HV power supply on the primary board as follows (figure 5):

- (+) Positive (clamp) to the PIN of connector JP2 on the resistor R75 side,

- (-) Negative (faston) to the negative faston of the diode bridge D19.

On the control board position the two potentiometers on minimum (R72, R77) and position switch S1 on MMA.

Figure F

Amplitude tollerance: ÷10%Frequency: 32,5Khz ÷ 10%Current scale: 50mV=500mA

SUPERIOR 240 CE

15

front panel on 12A, connect the machine to the 3-phase power figure I. supply 400 Vac and switch it on.

- With the load switched on, check that the voltage and current wave forms displayed on the oscilloscope resemble those in figure G.

Voltage at ends of load: 28,8V ±5%Current in load: 220A ±5%

Voltage at ends of load: 20,5V ±5%Current in load 12A ±5% NOTE. In order not to subject the static load generator to excess

overheating, do not leave the machine operating under these C) Average load test: conditions for a long. - Set up the static load generator with the switch settings as in the

table in figure H, on the front panel position the welding current E) Checking the secondary board diode voltages:potentiometer on 130A and switch on the machine. - Connect 2 voltage probes x100 between the 2 outlets of the power

- Check that the voltage and current wave forms displayed on the transformer on the secondary board (prods) and the shunt towards oscilloscope resemble those in figure H. the dissipator (earth).

- Connect the 2 probes to the oscilloscope and under the load conditions given in the table in figure I, switch on the machine and position the current potentiometer on maximum.

- Check that the voltage wave forms displayed on the oscilloscope resemble those in figure J.

Voltage at ends of load: 25,2V ±5%Current in load 130A ±5%

D) Rated load test:- Set up the static load generator with the switch settings as in the

table in figure I, on the front panel position the welding current F) Operational checks:potentiometer on 220A and switch on the machine. - Hot Start check.N.B. if the output current on the load is not 220A, adjust the current Set the static load generator so as to obtain a current of 100A±5% using trimmer R62 on the control board (figure 7) with a voltage of 24V±5% (Setting: 3-2-2-2-2-2) and keeping it

- Check that the voltage and current wave forms resemble those in switched off for the time being, set the Hot Start adjustment

Figure I

Figure H

Figure G

Figure J

Amplitude tollerance: ÷10%Current scale: 1V=10A

Amplitude tollerance: ÷10%Inverse voltage peak should not exceed 250V

Switch numberPosition number

Switch numberPosition number

Switch numberPosition number

Amplitude tollerance: ÷10%Current scale: 200mV=2A

Amplitude tollerance: ÷10%Current scale: 1V=10A

SUPERIOR 240 CE

16

potentiometer at 100% (figure 2A), then press the static load switch assemble the machine.on button. Check that the current measuring instrument on the front H) Welding test:panel of the static load generator is positioned at approx. 100A after With the machine preset as given in the instruction manual, in Electrode an initial peak. mode (S1 on the panel in the MMA position) and Arc Force at the

- Arc Force check. Set and switch on the static load so as to obtain a maximum, make a test weld with a 80A current (electrode 2.5 mm). current of 100A±5% with a voltage of 24V±5% (Setting: 3-2-2-2-2- Check the dynamic behaviour of the machine.2), set the Arc Force al adjustment potentiometer at 100% (figure

NOTE: It is also advisable to make a test weld, setting the parameters 2A) and decrease the welding current so that the voltage falls below using the remote control (choose the parameter values as desired 10V.referring to the Instruction Manual.Make sure that the current stabilises and then decreases abruptly

(short circuit protection cut-in: machine in alarm status). Warning: the adjustment range using CAD depends on the position of G) Running time check and closing the machine: the potentiometers on the machine front panel). - This test can be made at maximum current with two loads in parallel,

set to obtain a current of 220A±5% with a voltage of 28.8V±5%, or a current of 150A with only one load, set so as to obtain a current of 150A±5% with a voltage of 26±5%. In one of the 2 conditions (either) switch on the machine and leave it to operate until the thermostatic capsules cut in (machine in alarm status).

- Check the correct positioning of the internal wiring and finally re-

ILLUSTRATED REFERENCES

FIG. 1A

SCREWS

SCREWS

SCREWS

SUPERIOR 240 CE

17

FIG. 1B

FIG. 2A FIG. 2B

TOP COVER SCREWS

TOP COVER SCREW

POWERSUPPLY GREEN LED

CURRENTADJUSMENT

POTENTIOMETER

TOP COVER SCREW

FRONT BACK

HOT STARTAND ARC FORCE

ADJUSMENTPOTENTIOMETER

SCREWSFASTENING

BASE

POSITIVEDINSE SOCKET

NEGATIVEDINSE SOCKET

SCREWSFASTENING

BASE

POWERSUPPLY CABLE

SCREWSFASTENING

BASE

BACK FAN REMOTE CONTROL SOCKET

GENERALPOWER SUPPLY

SWITCH

YELLOWLED ALARM

SWITCHSECTIONMMA/TIG

FRONT FAN

SUPERIOR 240 CE

18

FIG. 3

FIG. 4

PRIMARY BOARDFASTENING SCREWS

SECONDARY BOARDFASTENING SCREWS

PRIMARY BOARD UPPER ASSEMBLY

REMOTECONTROL

WIRING

BASE

INPUTFILTERBOARD

CONTROLBOARD

R,S,T WIRING

R,S,TWIRING

SCREWSFASTENING BASE

PRIMARY BOARD

CONTROL BOARD

PRIMARY/CONTROLWIRING

POWERTRANSFORMER

(INSIDE)

PIN 1TRASFO

PIN 2TRASFO

SUPERIOR 240 CE

19

FIG. 5

FIG. 6

C6

C17

C45C38

D24IGBT

Q14, Q13, Q12

IGBTQ5, Q4, Q3

IGBT AND DIODEBRIDGE DISSIPATOR

C47OPTO-INSULATOR

BOARD BOX

U1U2 U3

D7

SCREWSFASTENING DIODES

SECONDARYSNUBBER SHUNT

POWERTRANSFORMERCONNECTIONS

POSITIVEDINSE

NEGATIVEDINSE

THERMOSTATICCAPSULE OF SECONDARY

DIODES DISSIPATOR

K1K2

SCREWSFASTENING DIODES

RECIRCULATINGDIODES

DIRECTDIODE

D2

D1

D5

D4

D3

FIG. 7

J3

J4

R62

J1

S1D35R72D8R77

SUPERIOR 240 CE

20

ELENCO PEZZI DI RICAMBIOLISTE PIECES DETACHEES

SPARE PARTS LISTERSATZTEILLISTE

PIEZAS DE REPUESTO

12624414313292305

17

16

20

8

18

25

21

111519282723129762210

Esploso macchina, Dessin appareil, Machine drawing, Explosions Zeichnung des Geräts, Diseño seccionado maquina.

SUPERIOR 240 CE

21

1

2

3

4

5

6

7

8

9

10

11

ELENCO PEZZI RICAMBIO TORCIA

LISTE PIECES DETACHEES TORCHE

SPARE PARTS LIST TORCH

ERSATZTEILLISTE SCLAUCHPAKET

PIEZAS DE REPUESTO ANTORCHA

ELENCO PEZZI RICAMBIO TORCIA

LISTE PIECES DETACHEES TORCHE

SPARE PARTS LIST TORCH

ERSATZTEILLISTE SCLAUCHPAKET

PIEZAS DE REPUESTO ANTORCHA

ELENCO PEZZI RICAMBIO TORCIA

LISTE PIECES DETACHEES TORCHE

SPARE PARTS LIST TORCH

ERSATZTEILLISTE SCLAUCHPAKET

PIEZAS DE REPUESTO ANTORCHA

CODE CODICE KODE

CODE CODICE KODE

CODE CODICE KODE

REF. REF. REF.

112017

112342

112048

113158

120241

122058

122962

122966

122508

132026

152214

PotenziometroPotentiometrePotentiometerPotentiometerPotenciometroRele'RelaisRelaisRelaisRelaisResistenzaResistanceResistorWiderstandResistenciaRaddrizzatoreRedresseurRectifierGleichrichterRectificadorCavoCableCableKabelCableManopola Per CommutatorePoignee Pour CommutateurSwitch KnobSchaltergriffManija Por ConmutadorCommutatoreCommutateurSwitchSchalterConmutadorDeviatoreCommutateurSwitchSchalterConmutadorTermostato 10,0AThermostat 10,0AThermal Switch 10,0AThermostat 10,0ATermostato 10,0ACavo Alim. 4G02.50 2.20 MCable Alim. 4G02.50 2.20 MMains Cable 4G02.50 2.20 MNetzkabel 4G02.50 2.20 MCable Alim. 4G02.50 2.20 MVentilatoreVentilateurFanVentilatorVentilador

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

ShuntShuntShuntShuntShuntTrasformatore Di Corrente TaTransformateur De Courant TaCurrent Transformer TaStromwandler TaTransformador De Corriente TaTrasformatore ImpulsiTrasformateur PulseePulse TransformerPulse TransformatorTransformador PulsadoKit Trasformatore + InduttanzaKit Tranformateur + ReactanceKit Transformer + ReactanceKit Trafo + ReaktanzKit Transformador + ReactanciaFibbiaBoucleBuckleSchnalleHebillaCinghiaCourroieBeltGurtCorreaCorniceCadreFrameRahmenMarcoFondoChassisBottomBodenteilFondoMantelloCapotCoverDeckelPanel De CoberturaPresa DinsePrise DixDinse SocketDinse SteckdoseEnchufe DinseKit Pressacavo + GhieraKit Presse Cable + EmboutKit Cable Bushing + Ring NutKit Kabelhalter + NutmutterKit Prensa Cable + Virola

Scheda FiltroPlatine FiltreFilter CardFilterkarteTarjeta FiltroKit Scheda PrimarioKit Fiche PrimaireKit Primary PcbKit PrimaertrafokarteKit Tarjeta PrimarioKit ManopolaKit PoigneeKnob KitGriff KitKit ManijaKit Scheda ControlloKit Platine De ControlKit Control PcbKit SteurungskarteKit Tarjeta De ControloKit Scheda SecondarioKit Fiche SecondaireKit Secundary PcbKit SekundÄrtrafokarteKit Tarjeta SecundarioKit DiodiKit DiodesKit DiodesKit DiodenKit DiodosKit IgbtKit IgbtKit IgbtKit IgbtKit IgbtCondensatoreCondensateurCapacitorKondensatorCondensador

152028

152231

152232

990591

322065

322408

322497

644186

655060

712036

990046

990287

990298

990328

990393

990394

990395

990396

113156

TECHNICAL REPAIR CARD.In order to improve the service, each servicing centre is requested to fill in the technical card on the following page at the end of every repair job. Please fill in this sheet as accurately as possible and send it to Telwin. Thank you in advance for your co-operation!

22

Official servicing centers

Repairing card Date:

Inverter :

Serial number:

Company:

Technician:

model

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

cription:Des

Dirty grade

Dirty inside the machine

Description:

Rectifier bridge

Electrolytic capacitors

Relais

In-rush limiter resistance

IGBT

Snubber

Secondary diodes

Potentiometer

Others

Kind of failure Component ref.Substitution of primary circuit board: yes noSubstitution of primary control board: yes no

Troubles evinced during repair :

SUPERIOR 240 CE

23

CERTIFIED QUALITY SYSTEM

ISO9001

TELWIN S.p.A. - Via della Tecnica, 336030 VILLAVERLA (Vicenza) Italy Tel. +39 - 0445 - 858811Fax +39 - 0445 - 858800 / 858801E-mail: telwin@telwin.com http://www.telwin.com