Service Manual

Ver. 1.1

150 150 VRD 151

Contents
Technical data.... 3 Operation principle. 4 Main circuit.... 4 - 6 Troubleshooting diagram... 7 Main ciruit diagrams. 8 Block diagram... 9 Operational tests / measurings.............. 10 Measurings........ 10, 11 Main transformer T001 prim. voltage... 12 Main transformer T001 sec. voltage..... 13 Voltage after sec. rectifier................. 14 Auxiliary coil voltage.... 15 Fan M001 voltage.......... 16 Pole voltage in OCV......... 16 Measuring points in the flat cable..... 17 Gate control, upper IGBTs.... 18 Gate control, lower IGBTs.... 19 Aux. voltage in DC-link.... 20 Signal lamp H2 control / VRD ON... 20 Main circuit card Z001 connectors.... 21 Main circuit card Z001 layout.... 22 Control card A001 layout... 23 Structure..24, 25 IGBT-transistor testing............... 26 Sec. diode testing............... 26 Notes.............. 27

Technical data
Minarc 150 Minarc 150 VRD Minarc 151

Supply voltage, 1~ 50/60 Hz 230 V 15% 230 V 15% 110 V 15% Loadability 35% ED (MMA) 140 A (7,5 kVA) 140 A (7,5 kVA) 140 A (7,5 kVA) 100% ED (MMA) 100 A (5,1 kVA) 100 A (5,1 kVA) 100 A (5,1 kVA) 35% ED (TIG) 150 A (5,0 kVA) 150 A (5,0 kVA) 150 A (5,0 kVA) 100% ED (TIG) 110 A (3,3 kVA) 110 A (3,3 kVA) 110 A (3,3 kVA) Supply cable / fuses 2,5 mm S / 3,3 m 16 A 2,5 mm S / 3,3 m 16 A 6 mm S / 2,0 m 32 A Welding current range (MMA) 10 A / 20,5 V140 A / 25,6 V 10 A / 20,5 V140 A / 25,6 V 10 A / 20,5 V140 A / 25,6 V Suitable stick sizes 1,53,25 mm 1,53,25 mm 1,53,25 mm Welding power adj. Stepless Stepless Stepless OCV ~ + 85 V ~ + 30 V ~ + 85 V Idling power < 10W < 10W < 10W Efficiency 0,8 0,8 0,8 Power factor 0,60 (140 A / 25.5 V) 0,60 (140 A / 25.5 V) 0,60 (140 A / 25.5 V) Temperature class B (130C) / H (180C) B (130C) / H (180C) B (130C) / H (180C) Operation temperature range -20+40C -20+40C -20+40C Stock temperature range -40+60C -40+60C -40+60C Casing class IP 23C IP 23C IP 23C Norms IEC 60974-1, -10 IEC 60974-1, -10 IEC 60974-1 EN 50199 EN 50199 EN 50199 Dimensions Length 320 mm 320 mm 320 mm Width 123 mm 123 mm 123 mm Height 265 mm 265 mm 265 mm Weight 4,0 (4,6) kg 4,0 (4,6) kg 4,4 (5,2) kg

Operation principle
Minarc power sources aredual-Forward inverters, controlled by PWM technology. Switching components are IGBT transistors. The operation frequency is ~ 80 kHz. Below is a picture of the dual-forward inverter operation principle. VDC 105 V1 0,5
Max.

~ + 320 V

1/3

t 13s

V2

When IGBTs V1 and V2 are non-conductive no power is transferred. Power is altered by changing the transistors timing (PWM).

Main circuit
X11/12
V16 C13 R9 V4, V5, V6

V20

X1

R31

X13
V21 V7, V3 L2 L1 C2, C3, C4

R32

C15

C5

X3

+t
R30

+t
C10 R23

C9

V11

T001

X12
V1, V2 T2 V8, V9, V10

X5

K1

Primary circuit connection, Minarc 150/150 VRD.

4

Main circuit
X11/7
R14 R17 R13 R8

X11/12
V16 C11

R9

X1
V6, V2 L1 L2 C2, C3

V3, V4, V5

X13

X2

R24

C16

X3
C10

C9

V10

T001

X12
V1, V11 C4, C5 T2 V7, V8, V9
L001

X4 X5

Primary circuit connection, Minarc 151.

C21

R34

V28, V29

X7
R21 R20

X003

X6 U
T001 V26, V27

V25

R35

R37

V26

X8 X9 X004

X11/11
V19 R11 V30

C20

V24

V28

X11/14
V23 C16

V22

R33

X10 X21
C14 C17 C19 R27 R36

X11/15
V18

R29

R24

V22

R25

X5

C18

X22

Secondary circuit connection, Minarc 150/151.

Main circuit
C21 R34 V28, V29 L001

X7
R21 R20

X003

X6 U
T001 V26, V27

V25

R35

R37

V26

X8 X9 X004

X11/11
V19 R11 V30

C20

V24

V28

X11/14
V23 C16

V22

R33

X10 X21
C14 C17 C19 R27 R36

X11/15
V18

R29

R24

V22

R25

X5

C18

X22

Secondary circuit connection, Minarc 150 VRD.

General
This machine may be repaired only by authorized repair shops and persons! The visual check must be done first, to find possible damages; loose wires, breaks and signs of overheating.

Troubleshooting diagram
DISTURBANCE Power source doesnt start; OCV ~ 0 V; POSSIBLE CAUSE Cooling fan M001 REMEDY Disconnect the fan connector X20 and start the power source again. If the power source starts and the OCV is ok, change the fan. Check the secondary diodes condition and change if needed. See the changing of secondary diodes, page 26. Check the primary side power semiconductors. If the voltage over the PTC R30 is more than ~ 230 Vac then there is a short circuit in the primary circuit. Change the faulty power semiconductor. See the IGBT transistor testing on page 26. Change the control card A001. Check the relay operation.

The rectifier diodes are in short circuit.

Faulty primary circuit power semiconductor.

The power source starts and the OCV rises up to ~85 V, after which the power source shuts down. Th epower source can not be loaded. The automatic fuses are blown during start up.

Faulty control card A001. Relay K1

Welding current cant be adjusted by potentiometer R001.

Faulty power adjustment potentiometer R001. Faulty control card A001.

Check the potentiometer condition (R001 = 10 k) Change control card A001.

Main circuit diagrams

Minarc 150/150 VRD

Minarc 151
8

Block diagram

A001 Controller (PWM) Gate buffer Set value circuit Voltage watch MMA ignition MMA dynamics Temperature control Supply voltage watch Auxiliary voltage watch TIG-locking TIG-scaling

Z001 Power stage EMI-filter DC-link charging Aux. voltages Voltage reserve circuit OCV controller Overvoltage protection

16

4
Z002 Relaycard

Minarc 151

Operational tests / measurings

Measuring point A. Main transformer T001 primary voltage Measuring point B. Main transformer T001 secondary voltage Measuring point C. Voltage after seconday rectifier Measuring point D. Aux. coil voltage Measuring point E. Fan M001 voltage Measuring point F. Pole voltage

10

Measuring points on main circuit card Z001 (Minarc 150)

A B C D E

Main transformer T001 primary Main transformer T001 secondary After the rectifier Main transformer auxiliary coil Fan M001

11

Measuring point A. Main transformer T001 primary voltage

Main transformer T001 primary voltage, min. (MMA)

Main transformer T001 primary voltage, max. (MMA)

12

Measuring point B. Main transformer T001 secondary voltage

Main transformer T001 secondary voltage, min. (MMA)

Main transformer T001 secondary voltage, max. (MMA)

13

Measuring point C. Voltage after secondary rectifier

Voltage after secondary rectifier, min. (MMA)

Voltage after secondary rectifier, max. (puikko)

14

Measuring point D. Auxiliary coil voltage

Auxiliary coil voltage, min. (MMA)

Auxiliary coil voltage, max. (MMA)

15

Measuring point E. Fan voltage

Idling

Min. load

Max. load

Measuring point F. Pole voltage on idling

Power adj. Potentiometer, min. Power adj. Potentiometer, max.

16

Measuring point on the flat cable

G H I J

X1/1 X1/2 X1/3 X1/4 X1/5 X1/6 X1/7 X1/8 X1/9 X1/10 X1/11 X1/12 X1/13 X1/14 X1/15 X1/16

GND Current info from primary GND Gate control, upper IGBTs Gate control, lower IGBTs GND Supply voltage watch Temperature watch (PTC:t) GND Auxiliary voltage (+2030 V) Signal lamp H2 control / VRD Auxiliary voltage from DC-link GND Auxiliary voltage +20 V OCV control (~ +85 V) GND

17

Measuring point G. Gate control, upper IGBTs

Gate pulse, min. (MMA)

Gate pulse, max. (MMA)

18

Measuring point H. Gate control, lower IGBTs

Gate pulse, min. (MMA)

Gate pulse, max. (MMA)

19

Measuring point I. Auxiliary voltage from DC-link

Measuring point J. Signal lamp H2 control / VRD ON

20

Main circuit card Z001 connectors (Minarc 150) X21 X15 X14 X16 X17 X18 X19 X20

X22 X9 X8

X13

X7 X10 X6 X11 X12

X1 X3 X5

X1, X3 X5 X6, X8 X7 X9 X10 X11 X12, X13 X14, X15 X16, X17 X18, X19 X20/1, 2 X21 X22

Supply voltage Protective earth Main transformer T001 sec. Sec. Choke L001 (+) X004 (-) X003 (+) Connection, A001 Main transformer T001 primary Main transformer T001 auxiliary coil PTC RT101 PTC RZ101 Fan M001 X003 (+) X004 (-)

21

Main circuit card Z001 layout (Minarc 150)

Main transformer X10

Smoothing capacitors

Secondary rectifier

X11

EMI

Primary rectifier EMI, DC-link charging LZ101 X5 X1, X3

22

Control card A001 layout

N1
Voltage regulator (+ 20 V)

X1 S1
MMA/TIG

N2
PWM-circuit

R26
Max. current adjustment

N3 Comparator R49
Current adjustment

R35
Min. current adjustment

H2
ON / VRD ON

H1
Overheat protection

N4
Comparator

23

Structure

Z001

A001

3 mm

T10 T15

T25

24

Structure

Extracting the control card A001

25

IGBT-transistor testing
Discrete-IGBTs (50 A, 600 V) can be tested with an IGBT tester. When changing damaged IGBTs, the whole series must be changed, plus the gate resistors (10)!! Discrete-IGBTs tightening torque to the heatsink is 0,61,2 Nm!
C2E1/1 B2/6
E2/2
C1/3

B1/4

IGBT-TESTER

TR 1

OFF ON

CONTROL

TR 2

Secondary diode testing

When testing secondary diodes the other coil end of the main transformer (T001) must be disconnected. Main transformer cable connectors may break if bent! If secondary diodes are in short circuit, then the power source will not start. The tightening torque for the secondary diodes is 0,61,2 Nm! The soldering must be done carefully, because they are stressed with high current, approximately 30 A/ leg!

26

Notes

27