Cod.

988367

SUPERIOR 240 CE

inver ter

TROUBLESHOOTING AND REPAIR MANUAL

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

30/06/02

reparation no-problem

MAINS INPUT

EMC FILTER

VARISTOR

PRE-CHARGE

RECTIFIER BRIDGE

FILTER

CHOPPER

PR.CURRENT CONTROL

TRANSFORMER

SEC. DIODES

NDUCTANCE SHUNT + -

SEC.EMC FILTER

OUTPUT

BLOCK DIAGRAM

10

11

OVERVOLTAGE SAFEGUARD FLYBACK POWER SUPPLY DRIVER CURRENT READER AND LIMITER PR. MAX. CURRENT LIMITER SHUNT AMPLIFIER

UNDERVOLTAGE SAFEGUARD

FAN

POWER SUPPLY LED

+ -

20 14
25
FUNCTION SELECTOR

21 26

36

35

12

13

MMA TIG-LIFT
27
ALARM BLOCK DUTY CYCLE MAKER ADDER
HOT START

SUPERIOR 240 CE

OPERATION AND WIRING DIAGRAMS

2
AUXILIARY POWER SUPPLY

17 29

15

16

33

DIODE THERMOSTAT SEC. DUTY CYCLE LIMITER CURRENT POTENTIOMETER

POWER TRANSFORMER THERMOSTAT

ALARM LED

ARC FORCE

SHORT CIRCUIT DETECTOR

22

23 27

19

34

18

30

28

PHASE FAILURE

SHORT CIRCUIT DELAY

HOT-START ARC-FORCE POTENTIOMETER

24

31

32

SUPERIOR 240 CE
ANALYSIS OF THE BLOCK DIAGRAM
NOTE: Unless indicated otherwise, it should be assumed that the components are assembled on the primary board or machine. Block 1 EMC Filter Consisting of: C1, C2, C3, C4, C5, C6, C7, L1, L2, L3 (input filter board) Prevents noise from the machine from being transmitted along the main power line and vice versa. Block 2 Varistor Consisting of: RV1, RV2, RV3 (input filter board) Prevents spike noise from the mains, with amplitude greater than 400V, from entering the machine. Block 3 Pre-charge Consisting of: K1, K2, R3, R9 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 relays K1 and K2 are de-energised, capacitors C6, C17, C22, C38, C45, C47 are then charged by R3 and R9. When the capacitors are charged the relays will be energised. Block 4 Rectifier bridge Consisting of: D19, D10 Converts the mains alternating voltage into continuous pulsed voltage. Block 5 Filter Consisting of: C6, C17, C22, C38, C45, C47 Converts the pulsed voltage from the rectifier bridge into continuous voltage. Block 6 Chopper Consisting of: Q3, Q4, Q5, Q12, Q13, Q14 Converts the continuous voltage from the filter into a high frequency square wave (32.5 kHz approx.) capable of piloting the power transformer. Regulates the power according to the required welding current/voltage. Block 7 Current transformer Consisting of: T1 The C.T. is used to measure the current circulating in the power transformer primary and transmit the information to block 14 (primary current reader and limiter). Block 8 Power transformer Consisting of: T1 Adjusts the voltage and current to values required for the welding procedure, also forming galvanic separation of primary from secondary (welding circuit from the power supply line).
3

Block 9 Secondary diodes Consisting of: D1, D2, D3, D4, D5 (secondary board) N.B. Some versions may have 4 power diodes (D1, D2, D3, D4) D1 and D2 make the current circulating in the transformer one-way, thus preventing saturation of the nucleus. D3, D4 and D5 recirculate the inductance output current when the IGBTs are not conducting, by-passing the transformer. Block 10 Inductance and shunt Consisting of: L1, R1 The inductance levels the secondary board diodes output current making it practically continuous/direct. The shunt reads the current circulating in the inductance and sends it to block 24/25 (amplifier shunt), which will process the data. Block 11 Secondary EMC Filter Consisting of: C1, C2 Prevents noise from the power source from being transmitted through the welding cables and vice versa. Block 12 Flyback power supply Consisting of: U4, Q6, T3, U1, U2, U3 Uses switching methods to transform and stabilise the voltage obtained from block 5 (filter) and supply 2 voltage values of 27V that enable block 13 (driver) to be powered correctly. It also generates a further three stabilized voltages (U1, U2, U3) of -12V, +5V and +12V which are mainly used to power the control board. Block 13 Driver Consisting of: U1 (opto-insulators board), Q7, Q8 and U2 (opto-insulators board), Q9, Q10. Takes the signal from block 12 (flyback power supply) and, controlled by block 15 (duty cycle maker), makes the signal suitable for piloting block 6 (chopper). Block 14 Primary current reader and limiter Consisting of: D1, R2, R55, R56, R57 R68 (control board) Picks up and limits the signal from block 7 (current transformer) and using R68 limits the maximum admissible primary current. This signal is also scaled down so that it can be processed and compared in block 15. Block 15 Duty cycle maker Consisting of: U2=UC3845 (control board) Processes the information from block 16 (adder) and block 14 (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. Block 16 Adder Consisting of: U1A, U1B (control board) Processes the information from blocks 18, 25, 27, 28 and

SUPERIOR 240 CE
sends it to block 15 (duty cycle maker). Block 17 Alarm Block Consisting of: Q1, D12, D13, R80, Q12 (control board) When an alarm is detected, the output current is cut off by operating directly on block 15 (duty cycle maker) in the event of: 1) Triggering of thermostatic capsule on secondary board dissipator diodes. 2) Triggering of thermostatic capsule on power transformer. 3) Triggering due to undervoltage. 4) Triggering due to overvoltage. 5) Phase loss at input. 6) Short circuit at output (electrode holder clamp and earth cable connected to each other or electrode stuck to piece being welded). Block 18 Potentiometer Consisting of: R72 (control board) Used to set the reference voltage needed to adjust the output current: changes the current from the minimum to the maximum value. Block 19 Yellow LED alarm light Consisting of: D35 (control board) It is switched on by block 17 (Alarm Block) if an alarm occurs. Block 20 Overvoltage safeguard Consisting of: U5A, R38, R40 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). Block 21 Undervoltage safeguard Consisting of: U5B, R30, R32 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). Block 22 Secondary diodes thermostat Consisting of: thermostatic capsule ST1 When the temperature of the secondary board dissipator reaches 70C (approx.) this safeguard triggers. Reset is automatic when the cause for alarm is removed. Block 23 Power transformer thermostat Consisting of: thermostatic capsule ST2 When the temperature of the power transformer is too high this safeguard triggers. Reset is automatic when the cause for alarm is removed. Block 24 Phase loss Consisting of: ISO2, ISO3 opto insulators board, U5C
4

(control board). If one of the three input phases is lost this alarm cuts in. Block 25 Shunt Amplifier Consisting of: U4 (control board) Amplifies the signal from block 10 (inductance shunt) and makes it appropriate for block 26 (maximum current limiter). Block 26 Maximum current limiter Consisting of: R62 (control board) Processes the information from block 25 (shunt amplifier) and, using R62, regulates the maximum welding current to be supplied by the power source. This signal is scaled down so that it can be processed and compared in l block 16 (adder). Block 27 Function selector Consisting of: S1 Uses the switch to select the type of welding process: MMA OR TIG-LIFT. Block 28 Short circuit detector Consisting of: U3B (control board) If the welding voltage P is lower than 10V this circuit causes block 30 to trigger (arc force) Block 29 Hot Start Consisting of: U3D, Q3, C9, Q2 (control board) When welding starts this block generates a temporary overcurrent, which can be adjusted by R72 and is used to pre-heat the electrode in MMA. Block 30 Arc Force Consisting of: Q7, C14, Q6 (control board) If the arc voltage falls below 10V, this block produces a temporary increase in output current, which is used to detach the electrode from the piece after sticking has occurred. Block 31 Short circuit delay Consisting of: U3A (control board) If output shorting persists, this block switches off the power source by means of block 17 (alarm block). Block 32 Hot-Start/Arc-Force Potentiometer Consisting of: R77 (control board) Used to set the reference voltage required to adjust the strike current percentage (0-100%) (Hot-Start) and the antistick overcurrent (Arc-Force). Block 33 Auxiliary Power Supply Consisting of: R111, R45, D15 (control board) This block reserves a voltage (about 11Vdc) for the shorting detection circuit so as to detect the shorting at output, if the power is disabled.

SUPERIOR 240 CE
Block 34 Duty Cycle Limiter Consisting of: U3C (control board) Limits the machine duty cycle under loadless operation. Block 35 Power supply LED Consisting of: green LED D8 (control board) Indicates when the machine is correctly powered and ready to weld. Block 36 Fan Consisting of: V1 andV2 Used to cool the power components and is powered by block 12 (at 12Vdc).

ILLUSTRATIONS
Input filter board
(1) EMC FILTER

(2) VARISTOR

(1) EMC FILTER

(3) RECTIFIER BRIDGE

(6) CHOPPER

(13) DRIVER

Primary board
OPTO ISOLATOR (U1,U2, ISO2, ISO3)

(5) FILTER

(4) PRECHARGE

(6) CHOPPER

(7) CURRENT TRANSFORMER

5

(12) FLYBACK POWER SUPPLY

SUPERIOR 240 CE
Secondary board
(22) SECONDARY DIODE THERMOSTAT

(9) DIODESECONDARY

Scheda secondario

(9) DIODESECONDARY

Control board
(14) PRIMARY CURRENT READER AND LIMITER (15) DUTY CYCLE MAKER (26) MAXIMUM CURRENT LIMITER

(16) RADER

(32) POTENTIOMETER HOT-START / ARC-FORCE

(27) FUNCTION SELECTOR (19) YELLOW LED ALARM LIGHT

(18) (35) POTENTIOMETER POWER SUPPLY GREEN LED CURRENT

SUPERIOR 240 CE
WIRING DIAGRAM
General wiring diagram

SUPERIOR 240 CE
Wiring diagram primary board - power

Wiring diagram primary board - driver

SUPERIOR 240 CE
Wiring diagram primary board - power supply

Wiring diagraminput filter board

Wiring diagram secondary board

SUPERIOR 240 CE
Wiring diagram control board

Wiring diagram control board

10

SUPERIOR 240 CE

REPAIR GUIDE
EQUIPMENT REQUIRED
6 5

1 4 3

2 7

9
1 2 3 4 5 6 Dual trace oscilloscope Static load generator Variac 0 - 500v 4500VA Digital multimeter Hall probe HV Power Supply

8
802401 (*) 802110 (*) 802440 (*) 802406 (*) 802403 (*)

ESSENTIAL INSTRUMENTS

USEFUL INSTRUMENTS
7 Unsoldering station

MISCELLANEOUS
8 Flat jaw pincers 9 Cutting nippers

(*) The instruments with codes can be supplied by Telwin. The sale price is available on request!
11

SUPERIOR 240 CE
HV POWER SUPPLY MODULE
THE HV POWER SUPPLY is used to ensure operation of the switching power supply (the circuit on the primary board supplying auxiliary voltages), even when the machine is operating at low voltage. It can be easily assembled by referring to the electrical diagrams in figure A and using the following components: T1 = insulation transformer 230-230V 50VA(*) D1 = rectifier bridge 36MB 80 (cod. 112357) C1 = electrolytic capacitor 470uF 400V ALL (cod.112514) R1 = resistor 10 ohm 5W 5% R2 = resistor 100K ohm 2W 5% F1 = delayed action fuse 1.5 A Fuse holder 5X20mm Female red and black faston Plastic box. working surfaces etc.). B) To ensure the heat flow between the electronic components and the dissipator, always place a thin layer of thermo-conductive grease (e.g. COMPOUND GREASIL MS12) between the contact zones. C) The power resistors (should they require replacement) should always be soldered at least 3 mm above the board. D) If silicone is removed from some points on the boards, it should be re-applied. N.B. Use only non-conducting neutral or oximic reticulating silicones (e.g. DOW CORNING 7093). Otherwise, silicone that is placed in contact with points at different potential (IGBT rheophores etc.) should be left to reticulate before the machine is tested. E) When the semi-conductor devices are soldered the maximum temperature limits should be respected (normally 300C for no more than 10 seconds). F) It is essential to take the greatest care at each disassembly and assembly stage for the various machine parts. 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). 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.

Figure A
ELECTRICAL DIAGRAM FOR POWER SUPPLY (HV OUTPUT):
F1 T1
10

R1
5

D1 R2

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

TROUBLESHOOTING REMEDIES
1) Disassembling the machine

AND

NOTE: To test the machine at low voltage special testing wiring should also be used so as to be able to force a number of alarm signals between the primary and control boards. This wiring is supplied with the HV power supply (or it can be obtained on request from Telwin: wiring KIT code 902760), or it can be easily assembled referring to the electrical diagram in figure B:

Figure B

Every 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). D) Separate the base from the upper metallic structure by removing the 4 screws fastening the one to the other and disconnecting (from the primary board) the 3 fastons R,S,T (J3,J4,J5) connecting the main power supply switch (figures 2A and 2B). E) Slide out the whole upper assembly (the structure anchoring the 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.

Connector to be fitted into control card

1 2 3 4 5 6

0.20 mm

2) Cleaning the inside of the machine

Connector to be fitted into primary card

Using compressed air, carefully clean the components of the power source since dirt is a danger to parts subject to high voltages and can 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. Primary board (figure 3): A) Rheophores of IGBT's Q3, Q4, Q5, Q12, Q13, Q14. B) Rheophores of recirculating diodes D7, D24. C) Rheophores of snubber network diodes D4, D27. D) Black box connection zone (it contains the board to which the driver
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GENERAL REPAIR INSTRUCTIONS

The following is a list of practical rules which must be strictly adhered to if repairs are to be carried out correctly. A) When handling the active electronic components, the IGBT's and Power DIODES in particular, take elementary antistatic precautions (use antistatic footwear and wrist straps, antistatic

SUPERIOR 240 CE
circuit opto-insulators are attached). Secondary board (figure 6): A) Power diodes D1, D2, D3, D4, D5. N.B. Some versions may have 4 power diodes (D1, D2, D3, D4) B) Thermostatic capsule on the dissipator 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). Parts fastened to the base (figure 4) If the primary and secondary boards are removed (with the diaphragm), clean the input filter carefully.

4) Checking power and signal wiring

It is important to check that all the connections are in good condition and the connectors are inserted and/or attached correctly. 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 cables should not come out of the fastons or connectors. 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-. 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). C) The power supply connections for the 2 fans to J9, J10, J11, J12). In particular on the secondary board (figure 6) the following checks should be made: A) Connections between the power transformer and the 2 secondary board bushes. B) Correct connection for the output equalisation inductance (between the secondary board bush and machine outlet OUT-). C) Connections to the shunt (secondary dissipator, shunt reader and shunt e positive machine outlet OUT+). D) The wiring between the thermostatic capsules on the secondary dissipator and the power transformer (connected in series).

3) Visual examination of the machine

Make sure there is no mechanical deformation, dent, or damaged and/or disconnected connector. Make sure the power supply cable has not been damaged or disconnected internally and that the fans work correctly with the machine switched on. Make a visual check of components listed below for signs of burning or breakage: A) Main power supply switch (figure 2B) Use the multimeter to check whether the contacts are stuck together or open. Probable cause: Mechanical or electrical shock (e.g. bridge rectifier or IGBT in short circuit, handling under load). B) Current potentiometer R72 (figure 2A) Probable cause: mechanical shock. C) Welding mode selector switch S1 (figure 2A) Probable cause: mechanical shock. D) Input filter board varistors (figure 4) Probable cause: power supply voltage much higher than 400Vac. E) Relays K1, K2 primary board (figure 5) Probable cause: See main power supply switch N.B. If the relay contacts are stuck together or dirty, do not attempt to detach them and clean them but replace the relay. F) Electrolytic capacitors C6, C17, C38, C45 primary board (figure 5) Probable cause: - mechanical shock - machine connected to a much higher line voltage than 400Vac, - broken rheophore on one or more capacitor: the remainder will be overstressed and become damaged by overheating, - aging after a considerable number of working hours, - overheating caused by thermostatic capsule operational failure G) IGBT's Q3, Q4, Q5, Q12, Q13, Q14 (figure 5) Probable cause: - discontinuation in snubber network, - fault in driver circuit , - poorly functioning thermal contact between IGBT and dissipator (e.g. loosened attachment screws:check), - excessive overheating related to faulty operation. H) Primary board diodes D4, D7, D24, D27 (figure 5) Probable cause: excessive overheating related to faulty operation. I) Secondary board diodes D1,D2,D3,D4,D5 (figure 6) Probable cause: - discontinuation in snubber network, - poorly functioning thermal contact between diodes and dissipator (e.g. loosened attachment screws:check), - faulty connection at machine outlet. J) Secondary board shunt R1 (figure 4) Check whether it has changed colour Probable cause: Overheating due to loosening of the screws connecting the shunts to the secondary circuits. K) Power transformer and filter inductance 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
13

5) Electrical measurements with the machine switched off

With the digital multimeter set for diode testing check the following components (junction voltages not less than 0.2V): A) Rectifier bridges D10, D19 (figure 5). B) IGBT's Q3, Q4, Q5, Q12, Q13, Q14 (absence of shor t circuits between collector-gate and between collector-emitter figure 5). C) Diodes D1, D2, D3, D4, D5 on secondary board between anode and cathode (figure 6). With the digital multimeter set on ohms check the following components: A) Resistors R3, R9: 47 ohm 5% 7W (precharge figure 5). B) Resistors R1, R2, R69, R71: 10 ohm 10% 11W (primary snubber figure 5). C) Resistor R1: 10 ohm 10% 5W (secondary snubber figure 6). D) Continuity test of the thermostatic capsules on the power transformer and secondary board dissipator: disconnect the fastons (so that the thermostats are connected in series) and measure the resistance over their ends, it should be about 0 ohm (figure 6).

6) Electrical measurements with the machine in operation

The tests described below can be used to check the workings of the power and control parts of the machine. Preparation for testing. A) Disconnect the fastons PIN1TRAFO (J8) and PIN2TRAFO (J2) of the power transformer from the primary board (figure 4). B) Set up the oscilloscope with the voltage probe x100 connected between the collector of Q6 (probe) and capacitor C47 from the Q3 side (earth) on the primary board (figure 5). C) On the primary board disconnect the jumper JP2. 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 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.

SUPERIOR 240 CE
Recommended tests. A) Switch on the HV power supply (HV output) and check that the precharge relays K1 and K2 on the primary board close with a slight delay (figure 5). B) Use the oscilloscope to check that the voltage waveform between the collector of Q6 (probe) and rheofore of C47 from the Q3 side (earth) resembles that shown in figure C. increase the voltage generated by the variac up to 24Vac. H) Set up the oscilloscope with the probe x10 connected between the gate (prod) and emitter (earth) of the IGBT Q3 on the primary board (figure 5). Check that the wave form on the display resembles that in figure E.

Figure E

Figure C

Amplitude tollerance: 10% Frequency: 32,5Khz 10% Amplitude tollerance: 10% Frequency: 32,5Khz 10%
C) On the primary board check the following power supply voltages: - between the cathode of D20 and the anode of D21 equal to +28V 5%, - between the cathode of D12 and the anode of D13 equal to +28V 5%, - between the anode of D11 and case of U3 equal to +12V5%, - between the anode of D6 and case of U3 equal to +5V5%, - between the cathode of D5 and case of U3 equal to 12V5%. B) Switch off the HV power supply, reposition the control board and reconnect the wiring with the exception of that between the primary board (to J1) and the control board (to J3). This should be replaced with the special test wiring as in figure B (take care to position correctly). 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 gate (prod) and emitter (earth) of the IGBT Q3 on the primary board (figure 5) Check that the wave form on the display resembles that in figure D. - 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, - reset the jumper JP2 on the primary board, - replace the test wiring between the primary and control boards with the original. J) Switch the machine back on and make sure that it is in alarm status (yellow LED D35 lit up on the panel). Increase the variac voltage to 320Vac and make sure the machine is always in alarm status. Continue to increase the variac voltage and check that between the values of 330Vac and 460Vac (approx.) the machine leaves alarm status. Finally, bring the variac voltage to 470Vac and make sure the machine does not return to alarm status (never take the variac above the value 475 Vac). Bring the variac immediately back down to 400Vac and switch off the machine.

7) Repairing and replacing the boards

If repairing the boards is complicated or impossible, they should be completely replaced. Each board is identified by a 6-digit code (printed 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. - Extract the board, rotating it gently upwards from the front panel side (this operation is easier if the front panel plate is pulled gently outwards). NB. For re-assembly proceed in the reverse order. Please read the procedure for replacing the IGBT's and/or rectifier bridges carefully: Even if only one IGBT is damaged, always replace all 6.
14

Figure D

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

- repeat this test on Q4, Q5, Q12, Q13, Q14 on the primary board. N.B. If the signal is not present and/or the machine is in alarm status (yellow LED lit up) there could be a fault in the control board (in which case we recommend its replacement) or in the IGBT driver circuit (figure 5). G) Switch off the HV reconnect the 2 fastons between the primary board and power transformer (J2 and J8). Switch on the HV and the variac (initially set to the value 0V), switch off the main power supply switch on the machine and gradually

SUPERIOR 240 CE
- On the board, removed from the machine, unscrew the 4 nuts fastening the dissipators and the 8 screws fastening the IGBTs and diode bridges (figure 5). - Disconnect the thermostat wiring from the connector JP1. - Before making the replacement check whether the components piloting the IGBT's are also damaged: - with the multimeter on ohms make sure there is no short circuit between the 1st and 3rd bump contacts of the printed circuit (between gate and emitter) for each component. - alternatively, the resistors R17, R19, R24, R45, R46, R47 could have burst and/or diodes D9, D14, D22 and D23 may be unable to function at the correct Zener voltage (this should have shown up in the preliminary tests). - Unsolder the components, clean the solder from the bump contacts and separate the board components. - Clean any irregularity or dirt from the dissipators. If the IGBT's have burst the dissipators may have been irreversibly damaged: in this case they should be replaced. - 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 - Join the dissipator/component assembly to the printed board, inserting all the rheofores in the bump contacts and the threaded spacers on the 4 attachment holes. - Attach the dissipators with the nuts and lock them once and for all in the following order: - the nuts fastening the dissipators to the printed circuit with a torque wrench setting of 2 Nm 20%; - the screws fastening the rectifiers to the dissipators with a torque wrench setting of 2 Nm 20%; - the screws fastening the IGBT's to the dissipators with a torque wrench setting of 1 Nm 20%. - Solder the terminals taking care not to let the solder run along them. - On the component side cut away the protruding part of the rheofores and check they are not shorted (especially the gate and emitter). NOTE. The 6 IGBT's should belong to the same selection kit supplied by 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 C) Control board If the fault is in the control board, we strongly advise its immediate replacement without further intervention.

TESTING THE MACHINE

The test should be carried out on the assembled machine before closing it with the top cover. During the tests with the machine in operation never commute the selectors or activate the noninductive load electromagnetic switch. Preparation for testing A) Using cables with suitable dinse sockets, connect the machine to the static load generator B) Connect a voltage probe x100 between the collector (prod) and emitter (earth) of Q5. C) Pass the current probe of the Hall effect transducer along the cable connecting the power transformer to the faston PIN2TRAFO (J2) with the reference arrow entering J2. D) Lastly, connect the Hall Probe and the voltage probe to the oscilloscope. E) Disconnect the jumper JP2 on the primary board. 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. G) Disconnect the wiring connecting the control board (J3) and primary board (J1) and replace it with the special test wiring as in figure B (as before). H) On the control board position the two potentiometers on minimum (R72, R77) and position switch S1 on MMA. I) Connect the machine power supply cable to the 3-phase variac with variable output 0-500 Vac. Recommended tests. A) No-load test: - With the static load generator disconnected first switch on the HV power supply and make sure that after a brief pause (green LED D8 and yellow LED D35 both lit up) the pre-charge relays K1 and K2 (figure 5) commute and the fans start operating. - 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 oscilloscope resemble those in figure F.

Figure F

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

- Switch off the machine, the variac and the HV power supply. - Disconnect the machine from the variac and the HV power supply. - Reset the jumper JP2 and the original wiring between the primary (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
15

SUPERIOR 240 CE
front panel on 12A, connect the machine to the 3-phase power 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. figure I.

Figure I

Figure G

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

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

Switch number Position number

Voltage at ends of load: 20,5V 5% Current in load 12A 5% C) Average load test: - 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 potentiometer on 130A and switch on the machine. - Check that the voltage and current wave forms displayed on the oscilloscope resemble those in figure H.

Switch number Position number

Voltage at ends of load: 28,8V 5% Current in load: 220A 5% NOTE. In order not to subject the static load generator to excess overheating, do not leave the machine operating under these conditions for a long. E) Checking the secondary board diode voltages: - Connect 2 voltage probes x100 between the 2 outlets of the power transformer on the secondary board (prods) and the shunt towards 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.

Figure H

Figure J

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

Switch number Position number

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 potentiometer on 220A and switch on the machine. N.B. if the output current on the load is not 220A, adjust the current using trimmer R62 on the control board (figure 7) - Check that the voltage and current wave forms resemble those in
16

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

F) Operational checks: - Hot Start check. Set the static load generator so as to obtain a current of 100A5% with a voltage of 24V5% (Setting: 3-2-2-2-2-2) and keeping it switched off for the time being, set the Hot Start adjustment

SUPERIOR 240 CE
potentiometer at 100% (figure 2A), then press the static load switch on button. Check that the current measuring instrument on the front panel of the static load generator is positioned at approx. 100A after an initial peak. - Arc Force check. Set and switch on the static load so as to obtain a current of 100A5% with a voltage of 24V5% (Setting: 3-2-2-2-22), set the Arc Force al adjustment potentiometer at 100% (figure 2A) and decrease the welding current so that the voltage falls below 10V. Make sure that the current stabilises and then decreases abruptly (short circuit protection cut-in: machine in alarm status). G) Running time check and closing the machine: - This test can be made at maximum current with two loads in parallel, set to obtain a current of 220A5% with a voltage of 28.8V5%, or a current of 150A with only one load, set so as to obtain a current of 150A5% with a voltage of 265%. 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 reassemble the machine. H) Welding test: With the machine preset as given in the instruction manual, in Electrode mode (S1 on the panel in the MMA position) and Arc Force at the maximum, make a test weld with a 80A current (electrode 2.5 mm). Check the dynamic behaviour of the machine. NOTE: It is also advisable to make a test weld, setting the parameters using the remote control (choose the parameter values as desired referring to the Instruction Manual. Warning: the adjustment range using CAD depends on the position of the potentiometers on the machine front panel).

ILLUSTRATED REFERENCES
FIG. 1A

SCREWS

SCREWS

SCREWS

17

SUPERIOR 240 CE
FIG. 1B
TOP COVER SCREWS

TOP COVER SCREW

TOP COVER SCREW

FIG. 2A

FRONT

FIG. 2B

BACK
BACK FAN

CURRENT ADJUSMENT HOT START POWER AND ARC FORCE SUPPLY GREEN LED POTENTIOMETER ADJUSMENT YELLOW POTENTIOMETER LED ALARM SWITCH SECTION MMA/TIG

REMOTE CONTROL SOCKET

FRONT FAN

SCREWS POSITIVE NEGATIVE FASTENING DINSE SOCKET DINSE SOCKET BASE

SCREWS FASTENING BASE

18

POWER SUPPLY CABLE

SCREWS FASTENING BASE

GENERAL POWER SUPPLY SWITCH

SUPERIOR 240 CE
FIG. 3
PRIMARY BOARD FASTENING SCREWS PRIMARY BOARD CONTROL BOARD

PRIMARY/CONTROL WIRING R,S,T WIRING POWER TRANSFORMER (INSIDE)

SCREWS FASTENING BASE

SECONDARY BOARD FASTENING SCREWS

FIG. 4

PRIMARY BOARD

PIN 1 TRASFO

PIN 2 TRASFO

UPPER ASSEMBLY CONTROL BOARD

REMOTE CONTROL WIRING

R,S,T WIRING BASE

INPUT FILTER BOARD

19

SUPERIOR 240 CE
FIG. 5
C45 C38 D24 IGBT Q14, Q13, Q12 C47 OPTO-INSULATOR BOARD BOX

C17 C6

K2 K1 D7 IGBT AND DIODE BRIDGE DISSIPATOR IGBT Q5, Q4, Q3

POWER TRANSFORMER CONNECTIONS

U1

U2 U3

FIG. 6
DIRECT DIODE SECONDARY SCREWS FASTENING DIODES SNUBBER SHUNT

POSITIVE DINSE

D2 D1

D5 D4 D3

RECIRCULATING DIODES

THERMOSTATIC CAPSULE OF SECONDARY SCREWS DIODES DISSIPATOR FASTENING DIODES

NEGATIVE DINSE

FIG. 7
J3

J4 R62

J1

R77

D8
20

R72

D35

S1

SUPERIOR 240 CE
ELENCO PEZZI DI RICAMBIO LISTE PIECES DETACHEES SPARE PARTS LIST ERSATZTEILLISTE PIEZAS DE REPUESTO
Esploso macchina, Dessin appareil, Machine drawing, Explosions Zeichnung des Gerts, Diseo seccionado maquina.

18 17 16 20 8 25 21

30

29

13

14

24

26

10

22

12
21

23

27

28

19

15

11

REF.

ELENCO PEZZI RICAMBIO TORCIA LISTE PIECES DETACHEES TORCHE SPARE PARTS LIST TORCH ERSATZTEILLISTE SCLAUCHPAKET PIEZAS DE REPUESTO ANTORCHA

CODE CODICE KODE

REF.

ELENCO PEZZI RICAMBIO TORCIA LISTE PIECES DETACHEES TORCHE SPARE PARTS LIST TORCH ERSATZTEILLISTE SCLAUCHPAKET PIEZAS DE REPUESTO ANTORCHA

CODE CODICE KODE

REF.

ELENCO PEZZI RICAMBIO TORCIA LISTE PIECES DETACHEES TORCHE SPARE PARTS LIST TORCH ERSATZTEILLISTE SCLAUCHPAKET PIEZAS DE REPUESTO ANTORCHA

CODE CODICE KODE

1 2 3 4 5 6 7 8 9 10 11

Potenziometro Potentiometre Potentiometer Potentiometer Potenciometro Rele' Relais Relais Relais Relais Resistenza Resistance Resistor Widerstand Resistencia Raddrizzatore Redresseur Rectifier Gleichrichter Rectificador Cavo Cable Cable Kabel Cable Manopola Per Commutatore Poignee Pour Commutateur Switch Knob Schaltergriff Manija Por Conmutador Commutatore Commutateur Switch Schalter Conmutador Deviatore Commutateur Switch Schalter Conmutador Termostato 10,0A Thermostat 10,0A Thermal Switch 10,0A Thermostat 10,0A Termostato 10,0A Cavo Alim. 4G02.50 2.20 M Cable Alim. 4G02.50 2.20 M Mains Cable 4G02.50 2.20 M Netzkabel 4G02.50 2.20 M Cable Alim. 4G02.50 2.20 M Ventilatore Ventilateur Fan Ventilator Ventilador

112017 112342 112048 113158 120241 122058 122962 122966 122508 132026 152214

12 13 14 15 16 17 18 19 20 21 22

Shunt Shunt Shunt Shunt Shunt Trasformatore Di Corrente Ta Transformateur De Courant Ta Current Transformer Ta Stromwandler Ta Transformador De Corriente Ta Trasformatore Impulsi Trasformateur Pulsee Pulse Transformer Pulse Transformator Transformador Pulsado Kit Trasformatore + Induttanza Kit Tranformateur + Reactance Kit Transformer + Reactance Kit Trafo + Reaktanz Kit Transformador + Reactancia Fibbia Boucle Buckle Schnalle Hebilla Cinghia Courroie Belt Gurt Correa Cornice Cadre Frame Rahmen Marco Fondo Chassis Bottom Bodenteil Fondo Mantello Capot Cover Deckel Panel De Cobertura Presa Dinse Prise Dix Dinse Socket Dinse Steckdose Enchufe Dinse Kit Pressacavo + Ghiera Kit Presse Cable + Embout Kit Cable Bushing + Ring Nut Kit Kabelhalter + Nutmutter Kit Prensa Cable + Virola

152028 152231 152232 990591 322065 322408 322497 644186 655060 712036 990046

23 24 25 26 27 28 29 30

Scheda Filtro Platine Filtre Filter Card Filterkarte Tarjeta Filtro Kit Scheda Primario Kit Fiche Primaire Kit Primary Pcb Kit Primaertrafokarte Kit Tarjeta Primario Kit Manopola Kit Poignee Knob Kit Griff Kit Kit Manija Kit Scheda Controllo Kit Platine De Control Kit Control Pcb Kit Steurungskarte Kit Tarjeta De Controlo Kit Scheda Secondario Kit Fiche Secondaire Kit Secundary Pcb Kit Sekundrtrafokarte Kit Tarjeta Secundario Kit Diodi Kit Diodes Kit Diodes Kit Dioden Kit Diodos Kit Igbt Kit Igbt Kit Igbt Kit Igbt Kit Igbt Condensatore Condensateur Capacitor Kondensator Condensador

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

SUPERIOR 240 CE

Official servicing centers Repairing card

Date: Inverter model: Serial number: Company: Technician: 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 Description:

Dirty grade Dirty inside the machine Description:

Kind of failure Component ref.

Rectifier bridge Electrolytic capacitors Relais In-rush limiter resistance IGBT Snubber Secondary diodes Potentiometer Others

Substitution of primary circuit board: yes Substitution of primary control board: yes Troubles evinced during repair :

no no

23

TELWIN S.p.A. - Via della Tecnica, 3 36030 VILLAVERLA (Vicenza) Italy Tel. +39 - 0445 - 858811 Fax +39 - 0445 - 858800 / 858801 E-mail: telwin@telwin.com http://www.telwin.com

9001
CERTIFIED QUALITY SYSTEM

ISO