Telwin Superior240 CE Troubleshooting And Repair Manual Download Page 11 | Manualshive

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ESSENTIAL INSTRUMENTS

1 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 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!

SUPERIOR 240 CE

EQUIPMENT REQUIRED

REPAIR GUIDE

REPAIR GUIDE

REPAIR GUIDE

REPAIR GUIDE

11

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Summary of Contents for Superior240 CE

Page 1: ...ons 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 SUPERIOR240CE ...

Page 2: ...NPUT EMC FILTER VARISTOR PRE CHARGE RECTIFIER FILTER CHOPPER PR CURRENT TRANSFORMER SEC DIODES NDUCTANCE SEC EMC OUTPUT BRIDGE CONTROL SHUNT FILTER UNDERVOLTAGE SAFEGUARD OVERVOLTAGE SAFEGUARD POWER SUPPLY LED FLYBACK POWER DRIVER CURRENT READER SUPPLY AND LIMITER PR PHASE FAILURE FUNCTION SELECTOR AUXILIARY POWER SUPPLY SHORT CIRCUIT DETECTOR ALARM BLOCK ADDER DUTY CYCLE MAKER DIODE THERMOSTAT SE...

Page 3: ...r bridge values of 27V that enable block 13 driver to be powered Consisting of D19 D10 correctly 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 13 Filter Driver Consisting of C6 C17 C22 C38 C45 C47 Consisting of U1 opto insulators bo...

Page 4: ...g of U3D Q3 C9 Q2 control board Consisting of U5A R38 R40 When welding starts this block generates a temporary If themain supplyvoltage exceeds themaximum 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 Force Bloc...

Page 5: ... 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 RECTIFIER BRIDGE 12 FLYBACK POWER SUPPLY 1 EMC FILTER ...

Page 6: ...OTENTIOMETER CURRENT 35 POWER SUPPLY GREEN LED 19 YELLOW LED ALARM LIGHT 27 FUNCTION SELECTOR 26 MAXIMUM CURRENT LIMITER 15 DUTY CYCLE MAKER 14 PRIMARY CURRENT READER AND LIMITER 32 POTENTIOMETER HOT START ARC FORCE Secondary board 22 SECONDARY DIODE THERMOSTAT 9 DIODESECONDARY 6 ...

Page 7: ...SUPERIOR 240 CE General wiring diagram WIRING DIAGRAM 7 ...

Page 8: ...SUPERIOR 240 CE Wiring diagram primary board power Wiring diagram primary board driver 8 ...

Page 9: ...Wiring diagraminput filter board 9 Wiring diagram primary board power supply Wiring diagram secondary board SUPERIOR 240 CE ...

Page 10: ...10 Wiring diagram control board Wiring diagram control board SUPERIOR 240 CE ...

Page 11: ...Digital multimeter 5 Hall probe 802406 6 HV Power Supply 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 SUPERIOR 240 CE EQUIPMENT REQUIRED REPAIR GUIDE REPAIR GUIDE REPAIR GUIDE REPAIR GUIDE 11 ...

Page 12: ...om 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 ...

Page 13: ...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 prechargefigure 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 snubberfigure 6 machine connected to a much higher line voltage than 400Vac D Continuity test of the therm...

Page 14: ...ted between the 7 Repairing and replacing the boards gate 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 infigure D in white on the component side after the initials TW This is the refe...

Page 15: ... 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 aw...

Page 16: ...nder 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 infigure 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 posi...

Page 17: ...d 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 ...

Page 18: ...SCREW FRONT BACK HOT START AND ARC FORCE ADJUSMENT POTENTIOMETER SCREWS FASTENING BASE POSITIVE DINSE SOCKET NEGATIVE DINSE SOCKET SCREWS FASTENING BASE POWER SUPPLY CABLE SCREWS FASTENING BASE BACK FAN REMOTE CONTROL SOCKET GENERAL POWER SUPPLY SWITCH YELLOW LED ALARM SWITCH SECTION MMA TIG FRONT FAN SUPERIOR 240 CE 18 ...

Page 19: ...NG SCREWS PRIMARY BOARD UPPER ASSEMBLY REMOTE CONTROL WIRING BASE INPUT FILTER BOARD CONTROL BOARD R S T WIRING R S T WIRING SCREWS FASTENING BASE PRIMARY BOARD CONTROL BOARD PRIMARY CONTROL WIRING POWER TRANSFORMER INSIDE PIN 1 TRASFO PIN 2 TRASFO SUPERIOR 240 CE 19 ...

Page 20: ...BOARD BOX U1 U2 U3 D7 SCREWS FASTENING DIODES SECONDARY SNUBBER SHUNT POWER TRANSFORMER CONNECTIONS POSITIVE DINSE NEGATIVE DINSE THERMOSTATIC CAPSULE OF SECONDARY DIODES DISSIPATOR K1 K2 SCREWS FASTENING DIODES RECIRCULATING DIODES DIRECT DIODE D2 D1 D5 D4 D3 FIG 7 J3 J4 R62 J1 S1 D35 R72 D8 R77 SUPERIOR 240 CE 20 ...

Page 21: ...E PARTS LIST ERSATZTEILLISTE PIEZAS DE REPUESTO 1 26 24 4 14 3 13 29 2 30 5 17 16 20 8 18 25 21 11 15 19 28 27 23 12 9 7 6 22 10 Esploso macchina Dessin appareil Machine drawing Explosions Zeichnung des Geräts Diseño seccionado maquina SUPERIOR 240 CE 21 ...

Page 22: ...omwandler 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 Bott...

Page 23: ...s 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 no Substitution of primary control board yes no Troubles evinced during...

Page 24: ...CERTIFIED QUALITY SYSTEM ISO 9001 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 ...

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