Telwin SUPERIOR TIG 362 AC/DC Troubleshooting And Repair Manual
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Telwin SUPERIOR TIG 362 AC/DC Troubleshooting And Repair Manual

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CONTENTS
REPAIR GUIDE.......................................................17
SPARE PARTS LIST...............................................30
REPAIR SHEET...................................................... 34
" r e p a r a t i o n
TROUBLESHOOTING
TROUBLESHOOTING
TROUBLESHOOTING
TROUBLESHOOTING
AND REPAIR MANUAL
AND REPAIR MANUAL
AND REPAIR MANUAL
AND REPAIR MANUAL
PAGE
2
3
6
8
17
18
18
18
22
n o
inver ter
p r o b l e m ! "
cod. 988593

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  • Page 1: Table Of Contents

    cod. 988593 inver ter TROUBLESHOOTING TROUBLESHOOTING TROUBLESHOOTING TROUBLESHOOTING AND REPAIR MANUAL AND REPAIR MANUAL AND REPAIR MANUAL AND REPAIR MANUAL CONTENTS PAGE OPERATION AND WIRING DIAGRAMS....2 - Block diagram - Analysis of the block diagram - Illustrations - Wiring diagrams REPAIR GUIDE............17 - Equipment required - General repair instructions...

  • Page 2: Operation And Wiring Diagrams

    SUPERIOR TIG 242-362 AC DC OPERATION AND WIRING DIAGRAMS OPERATION AND WIRING DIAGRAMS OPERATION AND WIRING DIAGRAMS OPERATION AND WIRING DIAGRAMS BLOCK DIAGRAM...

  • Page 3: Analysis Of The Block Diagram

    SUPERIOR TIG 242-362 AC/DC ANALYSIS OF THE BLOCK DIAGRAM Block 8 Secondary diodes NOTE: Unless indicated otherwise, it should be assumed that Consisting of: D1, D3, D4, D5, D6, D7, D8, D10 (Secondary board). the components are assembled on thewelding machine. Positive polarity diodes in the circuit: D1, D5 convert the current circulating in the positive OUT of the Block 1...
  • Page 4 SUPERIOR TIG 242-362 AC/DC Block 14 Block 20 IGBT Driver Overvoltage safeguard Consisting of: Q1, Q2, Q3, Q4 (primary board), optoisolator Consisting of: U5A, R38, R40 (power supply board) and part of board. primary board. Takes the signal from block 13 (flyback power supply) and, If the main supply voltage exceeds the maximum value this controlled by block 16 (duty cycle maker), makes the signal safeguard triggers (a tolerance of approx.
  • Page 5 SUPERIOR TIG 242-362 AC/DC Block 28 Block 36 Shunt Amplifier Hall sensor Solenoid valve relay Consisting of: U10 (control board 1 version). Consisting of: Q15, K4(control board). When the torch button is pressed, block 18 (microcontroller) Consisting of: U2 (control board 2 version) activates relay K4 which supplies the mains voltage needed to Amplifies the signal arriving from block 10 (Hall sensor), and power block 37 (solenoid valve).

  • Page 6: Illustrations

    SUPERIOR TIG 242-362 AC/DC ILLUSTRATIONS Primary board Power supply board (13) POWER SUPPLY PRIMARY FLYBACK BOARD BOARD CHOPPER FILTER PRE-CHARGE POWER SUPPLY (31) OPTOISOLATORS AUXILIARY CURRENT CHOPPER BOARD RECTIFIER BRIDGE TRANSFORMER TRANSFORMER Control board - 2 version Control board - 1 version (18) (18) MICROCONTROLLER...
  • Page 7 SUPERIOR TIG 242-362 AC/DC SUPERIOR TIG 242 Secondary board HF board, filter board (11) (37) HF BOARD HALL SECONDARY BOARD SOLENOID VALVE SENSOR INPUT FILTER CURRENT BOARD CONVERTER Secondary board SUPERIOR TIG 362 HF board, filter board (37) SOLENOID VALVE SECONDARY BOARD HF BOARD (11)

  • Page 8: Wiring Diagrams

    SUPERIOR TIG 242-362 AC DC WIRING DIAGRAMS General wiring diagram - 8 -...
  • Page 9 SUPERIOR TIG 242-362 AC/DC Wiring diagram primary board - Power Wiring diagram primary board - Driver - 9 -...
  • Page 10 SUPERIOR TIG 242-362 AC DC Wiring diagram power supply board Wiring diagram control board 1 version - Micro - 10 -...
  • Page 11 SUPERIOR TIG 242-362 AC/DC Wiring diagram control board 1 version - In/Out Wiring diagram control board 1 version - Analogic - 11 -...
  • Page 12 SUPERIOR TIG 242-362 AC DC Wiring diagram control board 2 version Wiring diagram control board 2 version - Analogic - 12 -...
  • Page 13 SUPERIOR TIG 242-362 AC/DC Wiring diagram control board 2 version - In/Out Wiring diagram control board 2 version - Micro - 13 -...
  • Page 14 SUPERIOR TIG 242-362 AC DC Wiring diagram control board 2 version - Peripherics Wiring diagram secondary board Superior Tig 242 - Power - 14 -...
  • Page 15 SUPERIOR TIG 242-362 AC/DC Wiring diagram secondary board Superior Tig 242 - Driver Wiring diagram secondary board Superior Tig 362 - Power - 15 -...
  • Page 16 SUPERIOR TIG 242-362 AC/DC Wiring diagram secondary board Superior Tig 362- Driver Wiring diagram HF board Wiring diagram input filter board - 16 -...

  • Page 17: Repair Guide

    3 Variac 0 - 300v 1500 VA cod. 802402 (*) 4 Digital multimeter 5 Hall Probe cod. 802406 (*) USEFUL INSTRUMENTS 6 Unsoldering station 7 Miscellaneous tools (*)The instruments with codes can be supplied by Telwin. The sale price is available on request. - 17 -...

  • Page 18: General Repair Instructions

    This wiring is supplied with the HV power supply (or it can be fig. 1A) - Undo the 14 screws fastening the top cover to the structure obtained on request from Telwin: wiring KIT code 902760), or it (figure 1B) can be easily assembled referring to the electrical diagram in...

  • Page 19: Auxiliary Transformer

    SUPERIOR TIG 242-362 AC/DC components of the power source since dirt is a danger to parts overheating caused by thermostatic capsule failure. ÷ subject to high voltages and can damage the galvanic separation IGBT's 1 10 primary board fig. 3 between the primary and secondary.

  • Page 20: Pre-Charge

    SUPERIOR TIG 242-362 AC/DC 5.0 Electrical measurements with the machine FIGURE C switched off A) With the multimeter set on diode testing check the following SETTINGS: · PROBE x100; components (joint voltages not less than 0.2V): · 200 V/Div; - rectifier bridges D1, D2, D3 ( fig.
  • Page 21 · 5 V/Div; · 5 sec/Div. µ component side after the initials TW). This is the reference code for requesting a replacement: Telwin may supply boards that are VERIFY THAT compatible but with different codes. · POSITIVE AMPLITUDE IS +15V ±10%;...

  • Page 22: Testing The Machine

    The IGBT's should belong to the same selection kit WARNING! Before proceeding to test the machine, we should supplied by Telwin. remind you that during these tests the power source is powered and therefore the operator is exposed to the danger of electric 7.3 Removing the secondary board (fig.
  • Page 23 SUPERIOR TIG 242-362 AC/DC 1.2 Scheduled tests - on the front panel position with the encoder the current at 150A; - start up the ohmic load and make sure that: Loadless test: - the waveforms displayed on the oscillscope resemble those Switch on the machine at 400Vac, set MMA mode on the front Fig.

  • Page 24: Operational Tests

    SUPERIOR TIG 242-362 AC/DC - the output current is equal to +350Adc±5% and the output Note: in case one of the two signals is not present or different from voltage is equal to +34Vdc ±5%; if the output current reading usual, the circuit driver of the IGBT module could be faulty.

  • Page 25: Illustrations

    SUPERIOR TIG 242-362 AC/DC ILLUSTRATIONS FIG. 1A SCRAW FASTENING HANDLE SCRAW SCRAW FASTENING FASTENING BACK PANEL FRONT PANEL AND CONTROL BOARD SCRAW FASTENING BACK PANEL SCRAW FASTENING FRONT PANEL FIG. 1B COVER SCRAWS BOTTOM COVER SCRAWS BOTTOM COVER SCRAWS - 25 -...

  • Page 26: Power Supply

    SUPERIOR TIG 242-362 AC/DC FIG. 2A FIG. 2B GENERAL SWITCH REMOTE CONNECTOR POWER TRANSFORMER INDUCTANCE SCRAWS SCRAWS SCRAWS SCRAWS VENTILATORE FASTENING FASTENING FASTENING FASTENING STRUCTURE STRUCTURE STRUCTURE STRUCTURE FAN SCRAWS MAINS CABLE GA STUBE NEGATIVE CONNECTOR CONNECTOR POSITIVE FASTENING CONNECTOR DINSE TIG TORCH GAS TORCH...
  • Page 27 SUPERIOR TIG 242-362 AC/DC FIG. 4 SUPERIOR TIG 242 HF BOARD SECONDARY BOARD FILTRE BOARD SOLENOID VALVE J1, J3 ISO1 G1, E1, ISO2 G2, E2 SUPERIOR TIG 362 FILTRE BOARD SOLENOID VALVE HF BOARD SECONDARY BOARD ISO2 HALL SENSOR J1, J3 ISO1 G1C, G1D, G2C, G2D, E1, G1A, G1B, G2A, G2B, E2...

  • Page 28: Control Board - 1 Version

    SUPERIOR TIG 242-362 AC/DC FIG. 5 Control board - 1 version R106 JP13 Control board - 2 version JP13 - 28 -...
  • Page 29 SUPERIOR TIG 242-362 AC/DC TAB. 1 MACHINE CYCLE 2T WITH HF ( ) - LIFT ( START ARC STRIKE WELDING WELDING WELDING DOWN POST END CYCLE CYCLE CURRENT CURRENT CURRENT SLOPE EV= OFF EV= ON EV= ON EV= ON EV= ON EV= ON EV= OFF EV= ON...

  • Page 30: Spare Parts List

    SUPERIOR TIG 242-362 AC/DC SUPERIOR TIG 242 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. 32 29 27 42 28 10 16 26 Per richiedere i pezzi di ricambio senza codice precisare: codice del modello;...
  • Page 31 SUPERIOR TIG 242-362 AC/DC ELENCO PEZZI DI RICAMBIO ELENCO PEZZI DI RICAMBIO ELENCO PEZZI DI RICAMBIO ELENCO PEZZI DI RICAMBIO ELENCO PEZZI DI RICAMBIO PIECES DETACHEES PIECES DETACHEES PIECES DETACHEES PIECES DETACHEES PIECES DETACHEES REF. REF. REF. REF. REF. SPARE PARTS LIST SPARE PARTS LIST SPARE PARTS LIST SPARE PARTS LIST...
  • Page 32 SUPERIOR TIG 242-362 AC DC SUPERIOR TIG 362 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. Esploso macchina, Dessin appareil, Machine drawing, Explosions Zeichnung des Geräts, Diseño seccionado maquina. Esploso macchina, Dessin appareil, Machine drawing, Explosions Zeichnung des Geräts, Diseño seccionado maquina.
  • Page 33 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!

  • Page 34: Repair Sheet

    SUPERIOR TIG 242-362 AC/DC Official servicing centers Repairing sheet 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 cription: Dirty grade...
  • Page 35 TELWIN S.p.A. - Via della Tecnica, 3 9001 36030 VILLAVERLA (Vicenza) Italy Tel. +39 - 0445 - 858811 Fax +39 - 0445 - 858800 / 858801 CERTIFIED QUALITY SYSTEM E-mail: telwin@telwin.com http://www.telwin.com UNI EN ISO 9001:2000...

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