Cod.988343 SUPERIOR PLASMA 90HF inver ter TROUBLESHOOTING AND REPAIR MANUAL CONTENTS PAGE OPERATION AND WIRING DIAGRAMS.........................2 Block diagram 2 Analysis of block diagram 3 Illustrations 5 Wiring diagrams 7 REPAIR GUIDE..............................................................12 Equipment required 12 General repair instructions 13 Troubleshooting and remedies 13 Testing the machine 17 Illustrations 20 SPARE PARTS LIST......................................................
MAINS INPUT INDUCTANCE THERMOSTAT 43 35 34 36 E- TORCH BUTTON PROTECTION HF 25 27 3 RECTIFIER BRIDGE AUXILIARY TRANSFORMER FAN 24 33 23 22 DIODE THERMOSTAT SEC.
SUPERIOR PLASMA 90 HF D3, D4 and D5 recirculate the inductance output current (block 9) while the IGBT's are not conducting, bypassing the power transformer(block 8). 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 10 Inductance and Hall sensors Consisting of: L1, Hall1 and Hall2 The inductance levels the output current from the secondary board diodes making it practically direct.
SUPERIOR PLASMA 90 HF Block 18 Block 25 Alarm block Consisting of: Q3, D12, D15 (control board) When an alarm is detected, the block drastically limits machine output current by acting directly on and changing the reference signal obtained from block 16 (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.
SUPERIOR PLASMA 90 HF Block 35 Block 38 HF safeguard Consisting of: D3, K4, C9, C8 (hf filter board) The HF safeguard is powered by block 34 (auxiliary transformer), at the instant when block 36 (torch button) is pressed relay K4 sends the signal to block 19 (microcontroller), which will process this information. The hf safeguard also separates the control board from the high frequency so as to prevent the residual signal from the torch button cables from entering the board.
SUPERIOR PLASMA 90 HF Secondary board (24) SECONDARY DIODE THERMOSTAT (9) DIODESECONDARY Control board (20) HALL SENSOR AMPLIFIERS (17) ADDER (21) MAXIMUM CURRENT CONTROL .
SUPERIOR PLASMA 90 HF WIRING DIAGRAMS General wiring diagram Wiring diagram input filter board 7
SUPERIOR PLASMA 90 HF Wiring diagram primary board - power Wiring diagram primary board - driver 8
SUPERIOR PLASMA 90 HF Wiring diagram control board - A Wiring diagram control board - B 9
SUPERIOR PLASMA 90 HF Wiring diagram control board - C Wiring diagram control board - D 10
SUPERIOR PLASMA 90 HF Wiring diagram HF filter board Wiring diagram secondary board Wiring diagram auxiliary control Wiring diagram HF filter board 11
SUPERIOR PLASMA 90 HF REPAIR GUIDE EQUIPMENT REQUIRED 5 1 2 4 6 3 8 7 ESSENTIAL INSTRUMENTS 1 2 3 4 5 Dual trace oscilloscope Static load generator Variac 0 - 500V 4500VA Digital multimeter Hall probe 802401 (*) 802111 (*) 802440 (*) 802406 (*) USEFUL INSTRUMENTS 6 Unsoldering station MISCELLANEOUS 7 Flat jaw pincers 8 Cutting nippers (*) The instruments with codes can be supplied by Telwin.
SUPERIOR PLASMA 90 HF 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, in particular IGBT's and power DIODES, take elementary precautions for electrostatic protection (such as wearing antistatic wristbands or footwear, using antistatic working surfaces etc.).
SUPERIOR PLASMA 90 HF Air inlet fan fastened to the back (fig. 2B) Check whether dirt is adversely affecting correct rotation of the blades; if there is still damage after cleaning replace the fan. Primary board (fig. 6): - rheofores of IGBT's 1 , 2, 3, 4, 5, 6, 7, 8, 9, 10; - rheofores of recirculating diodes D8, D10; - rheofores of snubber network diodes D6, D9; - zone for connection with the black box (contains the board to which the opto-isolators of the driver circuit are attached).
SUPERIOR PLASMA 90 HF transformer (E ALTO and C BASSO); the connections of the auxiliary transformer and to the auxiliary board; - the connections of the armoured resistors R1 and R2 to JP3A and JP3B. In particular it is necessary to make the following checks on the secondary board (fig.
SUPERIOR PLASMA 90 HF with different codes. Warning: before inserting a new board check it carefully for damage that may have occurred in transit. We supply boards that have already been tested and so if the fault is still present after correct replacement check the other machine parts. Unless the instructions explicitly require it, never adjust the trimmers on the boards. FIGURE D SETTINGS · PROBE CH1 x10; · 5 V/Div; · 10 µsec/Div.
SUPERIOR PLASMA 90 HF B) Removing the secondary board (fig. 5) Unless the dissipator has been damaged by a destructive explosion of the diodes, the secondary board should not generally be removed and the diodes can be replaced directly with the board mounted on the machine. In any case, it should be specified that to remove it is necessary to (fig.
SUPERIOR PLASMA 90 HF - if the output current on the load is not 90A, adjust it using R55 on the control board (fig. 7) disable the ohmic loads and switch off the machine at the main switch. D) Checking the secondary board diode voltages: - set up the dual trace oscilloscope by connecting probes CH1 and CH2 x100 to the secondary outputs of the power transformer.
SUPERIOR PLASMA 90 HF G) Checking torch operation (fig. K) If the load test was positive but arc strike is difficult or even impossible, the fault could be located in the torch.
SUPERIOR PLASMA 90 HF ILLUSTRATIONS SCREW SCREW SCREWS SCREWS SCREWS SCREWS SCREWS TOP COVER SCREWS BOTTOM 20
SUPERIOR PLASMA 90 HF YELLOE LED FOR PHASE FAILURE RED LED YELLOE LED YELLOW LED FOR GENERAL FOR AIR FAILURE FOR TORCH VOLTAGE ALARM SWITCH POST-AIR GREEN LED FOR POWER SUPPLY SCREWS FASTENING CONTROL BOARD SCREWS FASTENING CONTROL BOARD CURRENT POTENTIOMETER SCREWS FASTENING METAL STRUCTURE SCREWS FASTENING METAL STRUCTURE TORCHE PUSH BUTTON CONNECTOR MANOMETER DINSE SOCKET WORK CABLE CONNECTOR COMPRESSED AIR BACK FAN GENERAL POWER SUPPLY SWITCH FAN SCREWS FASTENING FAN SCREWS FASTENING MAINS
SUPERIOR PLASMA 90 HF CONTROL BOARD AUXILIARY TRANSFORMER HALL POWER SUPPLY AUXILIARY BOARD SENSOR PRIMARY BOARD POWER TRANSFORMER INDUCTANCE KIT SECONDARY BOARD BOTTOM SOLENOID VALVES PRESSURE SWITCH HF FILTER BOARD HF BOARD AUXILIARY CONTROL BOARD 22 INPUT FILTER BOARD
SUPERIOR PLASMA 90 HF HF TRANSFORMER SECONDARY THERMOSTAT DIODES D5, D4, D3 BOTTOM KIT SECONDARY BOARD DIODES D1, D2 SENSOR HALL R18 R17 C1 C5 C4 C2 SECONDARY SNUBBER C1A C4AC2A C5A IGBT R1, R2 D10 K1 K2 K3 C39 D3 R24 D2 R25 D1 OPTO ISOLATOR BOARD IGBT DISSIPATOR AND DIODES BRIDGE IGBT D9 D20, D22 D24, D25 PRIMARY THERMOSTAT FIG.
SUPERIOR PLASMA 90 HF 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.
SUPERIOR PLASMA 90 HF ELENCO PEZZI DI RICAMBIO PIECES DETACHEES SPARE PARTS LIST REF. ERSATZTEILLISTE PIEZAS DE REPUESTO Rele' Relais Relais Relais Relais Potenziometro Potentiometre Potentiometer Potentiometer Resistencia Elec.
SUPERIOR PLASMA 90 HF Esploso torcia, Dessin torche, Torch drawing, Schlauchpaket - Explosionszeichnung, Diseño seccionado antorcha. 3 1 6 7 8 9 5 11 12 REF.
SUPERIOR PLASMA 90 HF 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 Rectifier bridge Electrolytic capacitors Relais In-rush limiter resistance IGBT Snubber Secondary diodes
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