46700013-sm-minarc150-v1-1
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150
150 VRD
151
Service ManualVer. 1.1
Contents
Technical data………………………….……………...
Operation principle…………………………………….
Main circuit…………………………………….……...
Troubleshooting diagram………………………...……
Main ciruit diagrams………………………………….
Block diagram………………………………….……..
Operational tests / measurings…………...........……...
Measurings...……………………...…..
Main transformer T001 prim. voltage...
Main transformer T001 sec. voltage.....
Voltage after sec. rectifier..............…...
Auxiliary coil voltage..………………..
Fan M001 voltage..........………………
Pole voltage in OCV........…………….
Measuring points in the flat cable..…...
Gate control, upper IGBTs.…………...
Gate control, lower IGBTs.…………...
Aux. voltage in DC-link..………….….
Signal lamp H2 control / VRD ON..….
Main circuit card Z001 connectors.…………………...
Main circuit card Z001 layout…..……………………..
Control card A001 layout.……………………………..
Structure………………………………………………..
IGBT-transistor testing..............……………………….
Sec. diode testing.............……………………………..
Notes............…………………………………………..
3
4
4 - 6
7
8
9
10
10, 11
12
13
14
15
16
16
17
18
19
20
20
21
22
23
24, 25
26
26
27
Technical data
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 mm² S / 3,3 m 16 A 2,5 mm² S / 3,3 m 16 A 6 mm² S / 2,0 m 32 AWelding current range (MMA) 10 A / 20,5 V…140 A / 25,6 V 10 A / 20,5 V…140 A / 25,6 V 10 A / 20,5 V…140 A / 25,6 VSuitable stick sizes ø 1,5…3,25 mm ø 1,5…3,25 mm ø 1,5…3,25 mmWelding power adj. Stepless Stepless SteplessOCV ~ + 85 V ~ + 30 V ~ + 85 VIdling power < 10W < 10W < 10WEfficiency 0,8 0,8 0,8Power 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 (130°C) / H (180°C) B (130°C) / H (180°C) B (130°C) / H (180°C)Operation temperature range -20…+40°C -20…+40°C -20…+40°CStock temperature range -40…+60°C -40…+60°C -40…+60°CCasing class IP 23C IP 23C IP 23CNorms IEC 60974-1, -10 IEC 60974-1, -10 IEC 60974-1
EN 50199 EN 50199 EN 50199Dimensions
Length 320 mm 320 mm 320 mmWidth 123 mm 123 mm 123 mm
Height 265 mm 265 mm 265 mmWeight 4,0 (4,6) kg 4,0 (4,6) kg 4,4 (5,2) kg
Minarc 150 Minarc 150 VRD Minarc 151
3
Operation principle
VDC
t
105
13µs
Max
. 0,5
~ + 320 V
1/3
V1
V2
When IGBTs V1 and V2 are non-conductive no power is transferred. Power is altered by changing the transistor´s timing (PWM).
Main circuit
Minarc power sources are”dual-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.
+ t + t
X5
X1
X3
R31
R32
L2
C9
C5
C10
L1
R30 R23
C15
V21
V20
V11
C2,
C3,
C4 V
7, V
3
V1,
V2
V4,
V5,
V6
V8,
V9,
V10
T001
T2
K1
X11/12
V16
C13
R9
X13
X12
Primary circuit connection, Minarc 150/150 VRD.4
Main circuit
Secondary circuit connection, Minarc 150/151.
T001
U
R35
U
V28, V29
C21R34
R37
C20
V26
, V27
R33
X7
X9
L001X003
X004
X6
X8
R20
V25
V26
V24
R21
V19
R11
X11/11
X11/14
X11/15
V18
V23
V22
C18
R29
R24
R25
C16
V30V28
V22
C14
C17
X5
C19
R27
R36
X10
X21
X22
5
X5
X2
X3
R24
L1
C9
C10
L2
C16 V10
C2,
C3
V6,
V2
V1,
V11
V3,
V4,
V5
V7,
V8,
V9
T001
T2
X11/12
V16
C11
R9
X13
X12
X1
X4
R8R13R17R14
C4,
C5
X11/7
Primary circuit connection, Minarc 151.
T001
U
R35
U
V28, V29
C21R34
R37
C20
V26
, V27
R33
X7
X9
L001X003
X004
X6
X8
R20
V25
V26
V24R
21
V19
R11
X11/11
X11/14
X11/15
V18
V23
V22
C18R
29
R24
R25
C16
V30V28
V22
C14
C17
X5
C19
R27
R36
X10
X21
X22
Main circuit
Secondary circuit connection, Minarc 150 VRD.
6
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.
DISTURBANCE POSSIBLE CAUSE REMEDYPower source doesn´t start; OCV~ 0 V;
Cooling fan M001 Disconnect the fan connector X20and start the power source again. Ifthe power source starts and theOCV is ok, change the fan.
The rectifier diodes are in shortcircuit.
Check the secondary diodescondition and change if needed. Seethe changing of secondary diodes,page 26.
Faulty primary circuit powersemiconductor.
Check the primary side powersemiconductors. If the voltage overthe PTC R30 is more than ~ 230Vac then there is a short circuit inthe primary circuit. Change thefaulty power semiconductor. Seethe IGBT transistor testing on page26.
Faulty control card A001. Change the control card A001.The power source starts and theOCV rises up to ~85 V, afterwhich the power source shutsdown. Th epower source can notbe loaded. The automatic fusesare blown during start up.
Relay K1 Check the relay operation.
Welding current can´t be adjustedby potentiometer R001.
Faulty power adjustmentpotentiometer R001.
Check the potentiometer condition(R001 = 10 kΩ)
Faulty control card A001. Change control card A001.
Troubleshooting diagram
7
Main circuit diagrams
8
Minarc 150/150 VRD
Minarc 151
Block diagram
A001
Controller (PWM)Gate buffer
Set value circuitVoltage watchMMA ignition
MMA dynamicsTemperature controlSupply voltage watch
Auxiliary voltage watchTIG-lockingTIG-scaling
Z001
Power stageEMI-filter
DC-link chargingAux. voltages
Voltage reserve circuitOCV controller
Overvoltage protection
16
9
Z002
Relaycard
4
Minarc 151
Operational tests / measurings
A
B
C
Measuring point A. Main transformer T001 primary voltageMeasuring point B. Main transformer T001 secondary voltageMeasuring point C. Voltage after seconday rectifierMeasuring point D. Aux. coil voltageMeasuring point E. Fan M001 voltageMeasuring point F. Pole voltage
E
D
F
10
A Main transformer T001 primaryB Main transformer T001 secondaryC After the rectifierD Main transformer auxiliary coilE Fan M001
AB
C
D E
Measuring points on main circuit card Z001 (Minarc 150)
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
X1/1 GNDX1/2 Current info from primaryX1/3 GNDX1/4 Gate control, upper IGBTsX1/5 Gate control, lower IGBTsX1/6 GNDX1/7 Supply voltage watchX1/8 Temperature watch (PTC:t)X1/9 GNDX1/10 Auxiliary voltage (+20…30 V)X1/11 Signal lamp H2 control / VRDX1/12 Auxiliary voltage from DC-linkX1/13 GNDX1/14 Auxiliary voltage +20 VX1/15 OCV control (~ +85 V)X1/16 GND
G
H
I
J
Measuring point on the flat cable
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)
X3
X1
X6
X8
X9
X7
X14X15 X16 X17 X18
X19X20
X13
X12X10X11
X5
X21X22
X1, X3 Supply voltageX5 Protective earthX6, X8 Main transformer T001 sec.X7 Sec. Choke L001 (+)X9 X004 (-)X10 X003 (+)X11 Connection, A001X12, X13 Main transformer T001 primaryX14, X15 Main transformer T001 auxiliary
coilX16, X17 PTC RT101X18, X19 PTC RZ101X20/1, 2 Fan M001X21 X003 (+)X22 X004 (-)
21
Main circuit card Z001 layout (Minarc 150)
Smoo
thin
g ca
paci
tors
EMI
Primary rectifier
EMI, DC-link charging
X5LZ101
X1, X3
X11
Secondary rectifierX10
Main transformer
22
R26Max. currentadjustment
R35Min. currentadjustment
Control card A001 layout
R49Current adjustment
X1
S1MMA/TIG
H2ON / VRD ONH1Overheat protection
N1Voltage regulator(+ 20 V)
N2PWM-circuit
N3Comparator
N4Comparator
23
Structure
Z001A001
T10 T15 T25
3 mm
24
Structure
Extracting the control card A001
25
IGBT-transistor testing
G C E
IGBT-T
ESTE
R
TR 1
TR 2
CO
NTRO
L
OFF O
N
B2/6
C2E1/1
E2/2
C1/3
B1/4
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 (10Ω)!!
Discrete-IGBT´s tightening torque to the heatsink is 0,6…1,2 Nm!
Secondary diode testing
When testing secondary diodes the other coil end of the main transformer (T001) must be disconnected. Main transformercable connector´s 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 0,6…1,2 Nm!
The soldering must be done carefully, because they are stressed with high current, approximately 30 A/ leg!
26
Notes
27
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