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Service manual MinarcTig 180MLP

Version 1.0

MinarcTig 180MLP

Table of contents
Technical data......................................................................................3 Main circuit diagram........................................................................... 4 Block diagram..................................................................................... 5 Main circuit card Z001 Operating diagram............................................................... 6 Connectors........................................................................... 7 Measurings...........................................................................8 Control card A001 Operating diagram............................................................... 9 Connectors........................................................................... 10 Spark generator card A002 Connectors / operating diagram..........................................11 Panel card P001 Connectors / operating diagram..........................................12 Operating panel................................................................................... 13 Setup.................................................................................................... 14 Setup functions.................................................................................... 15-17 Error codes...........................................................................................18 Structure.............................................................................................. 19 Power semiconductors testing and replacing...................................... 20 Programming....................................................................................... 21 Troubleshooting...................................................................................22

Technical data
Mains voltage Rated power Load capacity TIG MMA TIG MMA Supply current, I1max Supply current, I1eff Connection cable / fuse Fuse Load capacity TIG MMA TIG MMA TIG MMA Welding range Open circuit voltage Idle Power TIG MMA TIG MMA TIG / MMA TIG / MMA 1 ~230 V 15%, 50 / 60 Hz Max. 6,7 kVA (180 A / 17,2 V) Max. 7,0 kVA (140 A / 25,6 V) 180 A / 17,2 V 120 A / 14,8 V 140 A / 25,6 V 100 A / 24 V 29 A (180 A/17,2 V) 31 A (140 A/25,6 V) 18 A (120 A/14,8 V) 22 A (100 A/24,0 V) 3 x 2,5 mm - 3 m Euro Schuko 16 A delayed 35 % ED 180 A/17,2 V 100 % ED 120 A/14,8 V 35 % ED 140 A/25,6 V 100 % ED 100 A/24 V 5 A/10,2 V-180 A/17,2 V 10 A/20,4 V-140 A/25,6 V 95 V 25 W 0,62 / 0,63 0,75 / 0,81 7-13 kV 1,5-3,25 mm (400 x 180 x 340) mm 7,8 kg (8,4 kg with supply cable) IP 23 C - 20 C+ 40 C > 7 kVA

35 % ED 100 % ED 35 % ED 100 % ED

Power ratio at max. current Efficiency at max. current Spark voltage MMA welding electrodes MMA External dimensions(L x W x H) Weight Degree of protection Operating temperature range Recommended generator

Main circuit diagram

PTC, 140 C Main switch, S1 Aux. transformer, T002

Main transformer, T001 Main circuit card

Choke, L002 PTC, 120 C Shunt resistor, R001

Spark transformer, T003 Spark generator card, A002

Control card

Panel card, P001

Solenoid valve, Y001 Fan, M001

Block diagram

Control card A001 Aux. Voltage development Undervoltage monitoring Over voltage monitoring Temperature monitoring Solenoid valve control Fan control Power supply control

Main circuit card Z001 Net over voltage protection DC-link charging EMI-filter Primary rectifier Energy reserve Dual-forward-inverter Main transformer Secondary rectifying

Panel card P001 Adjustment potentiometer Parameters selection Overheat protection signal light Main switch signal light

Spark generator card A002 Spark voltage generator (=voltage multiplier) Spark voltage adjustment

Main circuit card Z001


Secondary rectifier DC-link charging, resistors and relay Connector to A001 EMI-filter

Main transformer, T001 Current transformer, T1 IGBTs, gate resistors, return current diodes Smoothing capasitors

Primary rectifier

Operating diagram
- Net over voltage protection - DC-link charging - EMI-filter - Primary rectifier - Energy reserve - Dual-forward-inverter - Main transformer - Secondary rectifier

Z001

Connectors
X16 X5
A

X1

X3 X9 X10

X2 X12
B

X11 X13 X14 X15

X4

X1 X2 X3 X4 X5 X9 X10 X11 X12 X13 X14 X15 X16

Z001 connectors Power supply voltage 230 Vac Connector A001 Power supply voltage 230 Vac Shunt resistor, (-) Machine body, equipment earth Aux. transformer T002 supply voltage ~230 Vac Aux. transformer T002 supply voltage ~230 Vac Supply voltage to spark generator card A002 Supply voltage to spark generator card A002 Secondary choke L002, (+) PTC, main transformer PTC, main transformer Machine body, equipment earth

Measuring point A. X1, X3 Measuring point B. X2/6, X2/12 Measuring point C Primary rectifier

Measurings

Measuring point A. Supply voltage, main circuit card Z001

Measuring point B. Gate control pulse (X2/6, X2/12), no load

Measuring point C. DC-link charging (primary rectifier)

Control card A001


X1 X2 X3 H1

H2 X5 X8

X6 X9

X14

X13

Operating diagram
- Aux. Voltage development - PWM-control - Shunt amplifier - MMA dynamic control - Solenoid valve control - Fan control - Under voltage watch - Overvoltage watch - Overheat watch - Remote/foot control interface - TIG torch interface - Panel interface - Filtering of control lines

Connectors
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 A001 / X1 I2 measure U2 measure D1 data D1 data D1 data Torch potentiometer Remote potentiometer Current control D2 data D2 data D2 data Dynamics Powersource type Pedal start +5V GND A001 / X2 GND Relay + 24 V PTC Gate control Overvoltage, opto Relay on/off U2 measure PTC Gate control A001 / X5 X5/1 X5/2 X5/3 X5/4 X5/5 X5/6 X5/7 X6/1 X6/2 X6/3 X6/4 X6/5 X6/6 X6/7 GND 24 V Pedal start Remote pot +5V A001 / X6 GND SW 1 SW 2 Start Potentiometer +5V A001 / X8 X8/1 X8/2 21 Vac GND A001 / X9 X9/1 X9/2 I1 measure I1 measure A001 / X13 X13/1 X13/2 24 V GND

X2/1 X2/2 X2/3 X2/4 X2/5 X2/6 X2/7 X2/8 X2/9 X2/10 X2/11 X2/12

A001 / X3 X3/1 X3/2 H1 H2 PTC PTC Aux. voltage + 5 V (LED) Aux. voltage + 24 V (LED) X14/1 X14/2 X14/3 X14/4 X14/5 X14/6

A001 / X14 Spark on / off Solenoid valve (+) Spark on / off Solenod valve (-) -

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Spark generator card A002 Connectors


R9 X3 X2 X1 X2 X3 R9 A002 connectors Main transformer secondary Spark on / off Spark transformer primary Spark voltage adjustment

X1

Operating diagram
- Spark voltage generator (=voltage multiplier) - Spark voltage adjustment

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Panel card P001 Connectors

X2

X3

X10

P001 Connectors X1 Connector A001 X2 Membrane panel connection X10 Program-/service channel

X1

Operating diagram

- Micro controller (Renesas M30262) - Adjustment potentiometer - Parameters selection - Overheat protection signal light - Main switch signal light

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Operating panel

Standby indicator Minilog Upslope Pregas Selection arrow keys Process selection TIG / MMA 2T / 4T function and minilog

Overheating indicator Pulse cycle Downslope Postgas Pulse on/off Control knobb Panel / remote selector HF ignition ( LED on ) Contact ignition ( LED off )

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Setup

3 2

You can enter the Setup mode by pressing both arrow keys ( 1 ) for at least five seconds. The display will show the name of the parameter ( 2 ) and numerical value ( 3 ). Select the parameter to be adjusted with the arrow buttons ( 1 ), and change value with the control knob ( 4 ).

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Setup functions

Name on display A B C d E F h J L o S t

Parameter value range 0 or 1 0 or 1 0 or 1 0,1,2 or 3 5 40% 0 or 1 0.0 2.0s 0.0 10.0s 5.0 20.0s 15 99s -3 5 -9 0

Factory setting 0 0 0 1 20% 0 0s 1.0s 10.0s 30s 0 0

Description End current level selection. 1=5A, 0=15% Open-circuit voltage selection. 1=30V (VRD), 0=95V Forced stop during downslope with a brief pressing of the switch. 1=On, 0=Off Alternative switch logic. 0=4T LOG, 1=Minilog,( 2=4T-LOG+Minilog, 3= Minilog+ search arc ) Start current level as % of the welding current. Restore factory settings. 1=Restore, 0=No restore Minimum setting of pre-gas time. Minimum setting of post-gas time. Maximum setting of pre-gas time. Maximum setting of post-gas time. Arc dynamics (Arc Force) Electrode ignition pulse. -9=No pulse, 0=Max pulse

( Available from program version 0A7 )

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Setup functions
A = End current level selection With this function you can set the welding current level when the arc will be extinguished. 0 = 15% of the welding current that is used. 1 = minimum current, which is 5 amperes in this power source. B = Open-circuit selection With this function you can change the open-circuit voltage. 0 = 95 volts 1 = 30 volts C = Forced stop during downslope with a brief pressing on the switch When downslope time is adjusted, the welding current drops normally to the end current level and the arc is extinguished. This function allows to stop the arc during the downslope with a quick press from the switch. Works only with 2T. 0 = Off 1 = On d = Alternative switch logic With this function it is possible to choose between four different switch logics. 0 = 4T-LOG 1 = Minilog 2 = 4T-LOG + Minilog 3 = Minilog + Search arc E = Start current level selection (% of the welding current) With this function you can set the current level when the arc ignites. The value is a percentage of the welding current. The factory setting is 20%. If the welding current is set to 100A, the start current level is 20A. The adjustment range is 540%. F = Restore factory settings With this function you can reset the parameters to the factory settings. 0 = Do not restore factory settings 1 = Restore factory settings

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Setup functions
h = Minimum setting for pre-gas time With this function you can set the pre-gas minimum time to the desired value in the range 0 2 seconds.The factory setting is 0 seconds. J = Minumum setting for post-gas time With this function you can set the post-gas minimum time to the desired value in the range 0 10 seconds.The factory setting is 1 second L = Maximum setting for pre-gas time With this function you can set the pre-gas maximum time to the desired value in the range 5 20 seconds. The factory setting is 10 seconds. o = Maximum setting for post-gas time With this function you can set the post-gas maximum time to the desired value in the range 15 99 seconds. The factory setting is 30 seconds. S = Arc dynamics ( Arc Force ) When welding with MMA the power source automatically adjusts the dynamics. With this function it is possible to adjust the dynamics manually. Adjustment range is -3 - +5 -3 = ( softer arc ) +5 = ( harder arc ) t = Electrode ignition pulse When welding with MMA the power source automatically adjusts the ignition pulse. With this function it is possible to adjust the ignition pulse manually. Adjustment range is -9 0 -9 = No ignition pulse 0 = Maximum ignition pulse

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Error codes
E2: Power source undervoltage The machine has stopped because it has detected a mains undervoltage that disturbs welding. Check the quality of the supply network. E3: Power source overvoltage The machine has stopped the welding because it has detected momentary voltage spikes or continuous overvoltage dangerous to the machine in the electric network. Check the quality of the supply network E4: Power source overheating The power source has overheated. The cause may be one of the following. The power source has been used for a long time at maximum power The circulation of cooling air to the power source is blocked The cooling system has experienced a failure

Notice ! Remove any obstacle to air circulation, and wait until the power source fan has cooled down the machine.

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Structure
Membrane panel Panel card, P001 Control card, A001 Main switch, S001 Solenoid valve, Y001

Fan, M002

Spark generator card, A002 Main circuit card, Z001

Aux. transformer, T002 Choke, L002

Spark transformer, T003

Main transformer, T001

Shunt resistor, R001

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Power semiconductor testing and replacing


A separate discrete-IGBTs can be tested only when disconnected from the board with IGBT-tester. When replacing damaged IGBTs, the whole set has to be replaced, including gate resistors!! Discrete-IGBT and secondary diodes tightening torque to the heat sink is 0,61,2 Nm.

C2E1/1

B2/6

E2/2

C1/3

B1/4

IGBT-TESTER

TR 1

OFF ON

CONTROL

TR 2

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Programming

1. Start DataMaster II and press Menu. 2. Select Renesas Programming using UART mode. 3. Use the up and down arrows to choose the program you want to download. 4. Press START on the DataMaster II keypad to start the updating process. 5. When DataMaster II display says: Connect Programmable Device, connect DataMaster II (10-pin flat cable) to welding machine (panel card connector X10) and press CONTINUE. 6. Wait so long time that programming that Datamaster display shows: Programming Ok. 7. When updating is in progress, the DataMaster II display shows the progression of the process as a percentage value. If the progression stops, reset the DataMaster II by pressing ON/OFF key for 3 seconds, and start again.

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Troubleshooting
Problem Possible cause Remedy
Chech aux. Transformer T002 Secondary voltage between connectors X8/1-X8/2. (approx. 23 Vac) If aux. Transformer secondary voltage Is approx. 23 Vac, then replace control card A001 Check the primary side semiconductors. See IGBT-testing on page 23 Check aux. Transformer T002 condition Change membrane panel Check membrane panel functionality. Unconnect membrane connection from Panel card and check machine functionality Check the primary rectifier condition and solderings Check smoothing capasitors condition And solderings Check the secondary diodes and solderings Change control card A001 Check A002/X2-connector supply voltage Change spark generator card

The power doesnt start Aux transformer T002 Panels signal light (green) is not ignited

Control card A001

Th net fuses blow when starting machine

Faulty primary circuit semiconductor

Aux. transformer T002 Only program version is showing nn display Membrane panel is broken Membrane panel flat cabel is broken

The power source doesnt deliver full power

A faulty primary rectifier V9 A faulty smoothing capasitors A faulty secondary rectifier A faulty control card A001

TIG-high frequency spark doesnt ignite

A faulty spark generator card A002 A faulty Spark generator card A002

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