Cod.988367
SUPERIOR 240 CE
inverter
TROUBLESHOOTING AND REPAIR MANUAL
CONTENTS
PAGE
OPERATION AND ELECTRICAL DIAGRAMS................... DIAGRAMS................... 2
- Block diagram - Analysis of block diagram - Illustrations - Electrical diagrams
2 3 5 7
REPAIR GUIDE.................................................................. 11
- Equipment required - G e n e ra l r e p a i r i n s t r u c t i o n s - Troubleshooting and remedies - Testing the machine - Illustrations
11 12 12 15 17
SPARE PARTS PARTS LIST.......................................................... LIST.......................................................... 21 REPAIR SHEET................................................................. 23
30/06/02
“reparation no-problem”
SUPERIOR 240 CE
OPERATION AND WIRING DIAGRAMS BLOCK DIAGRAM T U P T U O
C R M E E . T C L I E F S
E C T N A N T U C H U S D + N
1 1
0 1
S E D O I D . C E S
9
R E M R O F S N A R T
8
T N E L O R R R T U N C . O C R P
R E P P O H C
7
E G R A H C E R P
R O T S I R A V
R E T L I F C M E
R E T I F N I U L H P S M A
T N E R R E R T I U C M . I X L A M
R . E R P D A R E E R T I T M N I E L R D R N U C A
R E V I R D
6
5
R E W O P K Y C L A P B P Y L U F S
4
Y L P P U S R E W D O E P L
R E T L I F
R E I E G F I D T I C R E B R
R E T E T E M C O R I A R T T O N S - E - F T C T O R O H A P
+ 5 2
T F R I N L O I O T T C G I C E T N L A E U F S M M
7 2
Y L P P Y U S R A R I L I E X W U O A P
T R A T S T O H
3 3
T I U C R I R C O T T C R E O T E H S D
8 2
Y A L E D
9 2
E C R O F C R A
6 1
R E T E M T O I N E T N R E R T U O C P
8 1
3 1
E L C Y C R Y E T K A U D M
5 1
E L C Y R C E T Y I T M U I D L
4 3
2 1
K C O L B M R A L A
7 1
6 2
R E D D A
4 1
D E L M R A L A
5 3
R E T A M T R S O F O R S M E N R W A E O R H P T T
6 3
3
N A F
2
E G A T D L R O V A U R E G E D F N A U S
1 2
1
E G A D T L R A O V U G R E E F V A O S
0 2
. C E S T A T S O E M R D E O I H D T
T U P N I S N I A M
2
2 3
0 3
T T I U R C O R H I S C
1 3
9 1
7 3 2
2 2
E R U L I A F E S A H P
4 2
SUPERIOR 240 CE Block 9
ANALYSIS OF THE BLOCK DIAGRAM
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 IGBT’s are not conducting, by-passing the transformer.
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 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 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 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 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 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 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 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 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 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 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).
Block 16 Adder Consisting of: U1A, U1B (control board) 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 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 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 18
Block 27
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.
Function selector Consisting of: S1 Uses the switch to select the type of welding process:MMA ORTIG-LIFT.
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 28 Block 19 Yellow LED alarm light Consisting of: D35 (control board) It is switched on by block 17 (Alarm Block) if an alarm occurs.
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
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).
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 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 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 22 Secondary diodes thermostat Consisting of: thermostatic capsule ST1 When the temperature of the secondary board dissipator reaches 70 C (approx.) this safeguard triggers. Reset is automatic when the cause for alarm is removed.
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 23 Power transformer thermostat Consisting of: thermostatic capsule ST2 When the temperature of the power transformeris too high this safeguard triggers. Reset is automatic when the cause for alarm is removed.
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.
Block 24 Phase loss Consisting of: ISO2, ISO3 opto insulators board, U5C 4
SUPERIOR 240 CE Block 34
Block 36
Duty Cycle Limiter Consisting of: U3C (control board) Limits the machine duty cycle under loadless operation.
Fan Consisting of: V1 andV2 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.
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
(7) CURRENT TRANSFORMER
(6) CHOPPER 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
(27) FUNCTION SELECTOR
(32) POTENTIOMETER HOT-START / ARC-FORCE
(18) (35) POTENTIOMETER POWER SUPPLY GREEN LED CURRENT
6
(19) YELLOW LED ALARM LIGHT
SUPERIOR 240 CE WIRING DIAGRAM
General wiring diagram
7
SUPERIOR 240 CE Wiring diagram primary board - power
Wiring diagram primary board - driver
8
SUPERIOR 240 CE Wiring diagram primary board - power supply
Wiring diagraminput filter board
Wiring diagram secondary board
9
SUPERIOR 240 CE Wiring diagram control board
Wiring diagram control board
10
SUPERIOR 240 CE
REPAIR GUIDE EQUIPMENT REQUIRED 6
5
1
2
4
7
3
9
8
ESSENTIAL INSTRUMENTS 1 Dual trace oscilloscope 2 Static load generator 3 Variac 0 - 500v 4500VA 4 Digital multimeter 5 Hall probe 6 HV Power Supply
802401 (*) 802110 (*) 802440 (*) 802406 (*) 802403 (*)
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 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 300°C 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.
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.
Figure A ELECTRICAL DIAGRAM FOR POWER SUPPLY (HV OUTPUT): F1
R1 T1
10
5
D1 R2
TROUBLESHOOTING REMEDIES
THE INSULATION TRANSFORMER CAN BE REPLACED WITH TWO TRANSFORMERS OF THE SAME POWER, CONNECTING THE SECONDARIES ACCORDING TO THE FOLLOWING DIAGRAM:
AND
1) Disassembling the machine 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).
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
After completing the repairs, proceed in reverse order to re-assemble the machine and fasten down the top cover and plastic covers. 1 2 3 4 5 6
Connector to be fitted into control card
0.20 mm2
2) Cleaning the inside of the machine 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.
Connector to be fitted into primary card
GENERAL REPAIR INSTRUCTIONS
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.
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
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 12
SUPERIOR 240 CE circuit opto-insulators are attached).
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 c apsules, shunts and out-.
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).
In particular on the primary board (figure 3) it is necessary 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).
Parts fastened to the base (figure 4) If the primary and secondary boards are removed (with the diaphragm), clean the input filter carefully.
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
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).
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. 13
SUPERIOR 240 CE 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.
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.
Figure E
Figure C
Amplitude tollerance: ÷10% Frequency: 32,5Khz ÷ 10% Amplitude tollerance: ÷10% Frequency: 32,5Khz ÷ 10%
- 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.
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 +12V±5%, - between the anode of D6 and case of U3 equal to +5V±5%, - between the cathode of D5 and case of U3 equal to –12V±5%. 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 s hould 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.
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.
Figure D
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.
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
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
SUPERIOR 240 CE - On the board, removed from the machine, unscrew the 4 nuts fastening the dissipators and the 8 screws fastening the IGBT’s 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).
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 variabl e 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.
NOTE.The 6 IGBT's should belong to the same selection kit supplied by Telwin.
Figure F
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
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.
C) Control board If the fault is in the control board, we strongly advise its immediate replacement without further intervention.
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 infigure G.
figure I.
Figure I
Figure G
Amplitude tollerance: ÷10% Current scale: 1V=10A
Amplitude tollerance: ÷10% Current scale: 200mV=2A
Switch number Position number
Switch number Position number
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 conditions for a long.
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.
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%
Amplitude tollerance: ÷10% Inverse voltage peak should not exceed 250V
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
F) Operational checks: - Hot Start check. Set the static load generator so as to obtain a current of 100A±5% with a voltage of 24V±5% (Setting: 3-2-2-2-2-2) and keeping it switched off for the time being, set the Hot Start adjustment 16
SUPERIOR 240 CE assemble 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.
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 100A±5% with a voltage of 24V±5% (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 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-
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 potentiometerson the machine front panel).
ILLUSTRATED REFERENCES FIG. 1A
SCREWS
SCREWS
SCREWS
17
SUPERIOR 240 CE FIG. 1B
TOP COVER SCREWS
TOP COVER SCREW
FIG. 2A
TOP COVER SCREW
FIG. 2B
FRONT
CURRENT ADJUSMENT HOT START POWER AND ARC FORCE SUPPLY GREEN LED POTENTIOMETER ADJUSMENT YELLOW POTENTIOMETER LED ALARM
BACK
REMOTE CONTROL SOCKET
BACK FAN
SWITCH SECTION MMA/TIG
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
C38
C45
IGBT Q14, Q13, Q12
D24
OPTO-INSULATOR BOARD BOX
C47
C17 C6
K2
K1 D7
IGBT Q5, Q4, Q3
IGBT AND DIODE BRIDGE DISSIPATOR
FIG. 6
DIRECT DIODE
U1
SECONDARY SCREWS FASTENING DIODES SNUBBER
SHUNT
U2 U3
POWER TRANSFORMER CONNECTIONS
POSITIVE DINSE
D2 D1
D5 D4 D3
RECIRCULATING DIODES
THERMOSTATIC CAPSULE OF SECONDARY SCREWS DIODES DISSIPATOR FASTENING DIODES
NEGATIVE DINSE
FIG. 7
J4 R62
J3
J1
R77
D8
R72 20
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 Geräts, Diseño seccionado maquina.
18 17
8
16
25
20
21
5
10
30
22
2
6
29
7
13
9
3
14
4
12
23 21
27
28
24
19
26
15
1
11
ELENCO PEZZI RICAMBIO TORCIA LISTE PIECES DETACHEES TORCHE
REF.
SPARE PARTS LIST TORCH ERSATZTEILLISTE SCLAUCHPAKET PIEZAS DE REPUESTO ANTORCHA
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
ELENCO PEZZI RICAMBIO TORCIA
CODE CODICE KODE
LISTE PIECES DETACHEES TORCHE
REF.
SPARE PARTS LIST TORCH ERSATZTEILLISTE SCLAUCHPAKET PIEZAS DE REPUESTO ANTORCHA
112017
12
112342
13
112048
14
113158
15
120241
16
122058
17
122962
18
122966
19
122508
20
132026
21
152214
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
ELENCO PEZZI RICAMBIO TORCIA
CODE CODICE KODE
LISTE PIECES DETACHEES TORCHE
REF.
SPARE PARTS LIST TORCH ERSATZTEILLISTE SCLAUCHPAKET PIEZAS DE REPUESTO ANTORCHA
152028
23
152231
24
152232
25
990591
26
322065
27
322408
28
322497
29
644186
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 SekundÄrtrafokarte 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
CODE CODICE KODE
990287 990298 990328 990393 990394 990395 990396 113156
655060 712036 990046
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 Des cription:
Dirty grade Dirty inside the machine Description: Kind of failure Rectifier bridge Electrolytic capacitors
Component ref.
Substitution of primary circuit board: yes Substitution of primary control board: yes Troubles evinced during repair :
Relais In-rush limiter resistance IGBT Snubber Secondary diodes Potentiometer Others 23
no no
TELWIN S.p.A. - Via della Tecnica, 3
36030 VILLAVERLA (Vicenza) Italy Tel. +39 - 0445 - 858811 Fax +39 - 0445 - 858800 / 858801 E-mail:
[email protected] http://www.telwin.com
ISO
9001 CERTIFIED QUALITY SYSTEM
