Minarc 150,151 Service Manual | Transformer | Rectifier

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

1 kVA) 35% ED (TIG) 150 A (5.5 V…140 A / 25.0 kVA) 150 A (5. Stepless Stepless Stepless OCV ~ + 85 V ~ + 30 V ~ + 85 V Idling power < 10W < 10W < 10W Efficiency 0.5 kVA) 140 A (7.0 m 32 A Welding current range (MMA) 10 A / 20.8 0.5…3.3 kVA) Supply cable / fuses 2.5 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°C Stock temperature range -40…+60°C -40…+60°C -40…+60°C Casing class IP 23C IP 23C IP 23C Norms IEC 60974-1.4 (5.5…3.25 mm ø 1.25 mm ø 1.5…3.6 V 10 A / 20.5 kVA) 100% ED (MMA) 100 A (5.6) kg 4. -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 4.3 m 16 A 6 mm² S / 2.60 (140 A / 25.0 kVA) 150 A (5.60 (140 A / 25.8 0. -10 IEC 60974-1.5 V…140 A / 25.5 V) 0.5 kVA) 140 A (7. 1~ 50/60 Hz 230 V ± 15% 230 V ± 15% 110 V ± 15% Loadability 35% ED (MMA) 140 A (7.8 Power factor 0.6 V Suitable stick sizes ø 1.5 V) 0.5 mm² S / 3.0 kVA) 100% ED (TIG) 110 A (3.5 V…140 A / 25.0 (4.3 m 16 A 2.0 (4.1 kVA) 100 A (5.25 mm Welding power adj.3 kVA) 110 A (3.6) kg 4.5 mm² S / 3.60 (140 A / 25.3 kVA) 110 A (3.1 kVA) 100 A (5.2) kg 3 .Technical data Minarc 150 Minarc 150 VRD Minarc 151 Supply voltage.6 V 10 A / 20.

4 . controlled by PWM technology. V2 T2 V8. Minarc 150/150 VRD. C4 R32 C15 C5 X3 +t R30 +t C10 R23 C9 V11 T001 X12 V1. ~ + 320 V 1/3 t 13µs V2 When IGBTs V1 and V2 are non-conductive no power is transferred. V10 X5 K1 Primary circuit connection. V9.Operation principle Minarc power sources are”dual-Forward” inverters. C3. VDC 105 V1 0. V3 L2 L1 C2. V5. V6 V20 X1 R31 X13 V21 V7. Main circuit X11/12 V16 C13 R9 V4. Below is a picture of the ”dual-forward” inverter operation principle. The operation frequency is ~ 80 kHz.5 Max. Switching components are IGBT transistors. Power is altered by changing the transistor´s timing (PWM).

V8. V11 C4. V2 L1 L2 C2. V5 X13 X2 R24 C16 X3 C10 C9 V10 T001 X12 V1. 5 . V4. V9 L001 X4 X5 Primary circuit connection.Main circuit X11/7 R14 R17 R13 R8 X11/12 V16 C11 R9 X1 V6. C21 R34 V28. Minarc 151. C3 V3. C5 T2 V7. V29 X7 R21 R20 X003 X6 U T001 V26. Minarc 150/151. V27 V25 R35 R37 V26 X8 X9 X004 X11/11 V19 R11 V30 C20 V24 V28 X11/14 V23 C16 V22 R33 U X10 X21 C14 C17 C19 R27 R36 X11/15 V18 R29 R24 V22 R25 X5 C18 X22 Secondary circuit connection.

6 . V29 L001 X7 R21 R20 X003 X6 U T001 V26. Minarc 150 VRD.Main circuit C21 R34 V28. V27 V25 R35 R37 V26 X8 X9 X004 X11/11 V19 R11 V30 C20 V24 V28 X11/14 V23 C16 V22 R33 U X10 X21 C14 C17 C19 R27 R36 X11/15 V18 R29 R24 V22 R25 X5 C18 X22 Secondary circuit connection.

Change the faulty power semiconductor. Relay K1 Welding current can´t be adjusted by potentiometer R001. Faulty control card A001. POSSIBLE CAUSE Cooling fan M001 REMEDY Disconnect the fan connector X20 and start the power source again.General This machine may be repaired only by authorized repair shops and persons! The visual check must be done first. Troubleshooting diagram DISTURBANCE Power source doesn´t start. Faulty power adjustment potentiometer R001. Check the potentiometer condition (R001 = 10 kΩ) Change control card A001. loose wires. The power source starts and the OCV rises up to ~85 V. Faulty primary circuit power semiconductor. Check the relay operation. The rectifier diodes are in short circuit. See the changing of secondary diodes. page 26. to find possible damages. If the voltage over the PTC R30 is more than ~ 230 Vac then there is a short circuit in the primary circuit. OCV ~ 0 V. 7 . Faulty control card A001. See the IGBT transistor testing on page 26. breaks and signs of overheating. Check the secondary diodes condition and change if needed. Th epower source can not be loaded. after which the power source shuts down. Check the primary side power semiconductors. If the power source starts and the OCV is ok. The automatic fuses are blown during start up. change the fan. Change the 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 9 .

Aux. coil voltage Measuring point E. Main transformer T001 secondary voltage Measuring point C.Operational tests / measurings C F E B A D Measuring point A. Pole voltage 10 . Fan M001 voltage Measuring point F. Voltage after seconday rectifier Measuring point D. Main transformer T001 primary voltage Measuring point B.

Measuring points on main circuit card Z001 (Minarc 150) D E C B A A B C D E Main transformer T001 primary Main transformer T001 secondary After the rectifier Main transformer auxiliary coil Fan M001 11 .

(MMA) 12 . Main transformer T001 primary voltage Main transformer T001 primary voltage. (MMA) Main transformer T001 primary voltage. max.Measuring point A. min.

max. (MMA) Main transformer T001 secondary voltage.Measuring point B. min. Main transformer T001 secondary voltage Main transformer T001 secondary voltage. (MMA) 13 .

Measuring point C. Voltage after secondary rectifier Voltage after secondary rectifier. (puikko) 14 . min. (MMA) Voltage after secondary rectifier. max.

(MMA) 15 . min.Measuring point D. (MMA) Auxiliary coil voltage. Auxiliary coil voltage Auxiliary coil voltage. max.

min. Potentiometer. Fan voltage Idling Min. load Max.Measuring point E. Power adj. max. Potentiometer. 16 . Pole voltage on idling Power adj. load Measuring point F.

upper IGBTs Gate control. lower IGBTs GND Supply voltage watch Temperature watch (PTC:t) GND Auxiliary voltage (+20…30 V) Signal lamp H2 control / VRD Auxiliary voltage from DC-link GND Auxiliary voltage +20 V OCV control (~ +85 V) GND 17 .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.

(MMA) 18 . max. upper IGBTs Gate pulse. (MMA) Gate pulse.Measuring point G. min. Gate control.

Measuring point H. Gate control. lower IGBTs Gate pulse. min. (MMA) 19 . (MMA) Gate pulse. max.

Auxiliary voltage from DC-link Measuring point J. Signal lamp H2 control / VRD ON 20 .Measuring point I.

Sec. X17 X18.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. 2 X21 X22 Supply voltage Protective earth Main transformer T001 sec. X13 X14. X8 X7 X9 X10 X11 X12. X19 X20/1. Choke L001 (+) X004 (-) X003 (+) Connection. A001 Main transformer T001 primary Main transformer T001 auxiliary coil PTC RT101 PTC RZ101 Fan M001 X003 (+) X004 (-) 21 . X3 X5 X6. X15 X16.

DC-link charging LZ101 X5 X1. X3 22 .Main circuit card Z001 layout (Minarc 150) Main transformer X10 Smoothing capacitors Secondary rectifier X11 EMI Primary rectifier EMI.

current adjustment N3 Comparator R49 Current adjustment R35 Min.Control card A001 layout N1 Voltage regulator (+ 20 V) X1 S1 MMA/TIG N2 PWM-circuit R26 Max. 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 .

6…1. Main transformer cable connector´s may break if bent! If secondary diodes are in short circuit. plus the gate resistors (10Ω)!! Discrete-IGBT´s tightening torque to the heatsink is 0.IGBT-transistor testing Discrete-IGBTs (50 A.6…1. The tightening torque for the secondary diodes is 0. the whole series must be changed. then the power source will not start.2 Nm! C2E1/1 B2/6 E2/2 C1/3 G C E 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. When changing damaged IGBTs. 600 V) can be tested with an IGBT tester. approximately 30 A/ leg! 26 . because they are stressed with high current.2 Nm! The soldering must be done carefully.

Notes 27 .

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