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
0,5

~ + 320 V

Max.

V1

1/3

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
C13

V16
V20

X1

V4, V5, V6

R9

X11/12

T2

C9

T001

X12

V8, V9, V10

R23

V1, V2

R30

V11

C2, C3, C4

+t

C5

C15

+t

C10

V21
R32

X3

L1

V7, V3

R31

X13
L2

X5

K1

Primary circuit connection, Minarc 150/150 VRD.

4

Main circuit
R17

R13

R8

R9

C11

V16

X11/12

V3, V4, V5

X11/7

R14

X1

T001

V6, V2

L2

V10

C9

C16

R24

L1

C2, C3

X13

X2

X3

V7, V8, V9

X5

T2

C4, C5

C10

V1, V11

X12

X4

Primary circuit connection, Minarc 151.

C21

R34

V28, V29
L001

X003

X6

R20

R21

X7

V26

R33

C20

V24

V26, V27

R35

R37

V25

T001

X8

X11/11

X9

X004

V19
V30

R11

V28

V22

X5

C18

R36

R27

C19

C17

X21
C14

R25

V22

V18

R24

R29

X11/15

X10

C16

V23

X11/14

X22

Secondary circuit connection, Minarc 150/151.

Main circuit
C21

R34

V28, V29
L001

X003

X6

R20

R21

X7

V26

R33

V26, V27

C20

V24

R37

V25

T001

U
R35

X8

X11/11

X9

X004

V19
V30

R11

V28

V22

X5

C18

R36

R27

C19

C17

X21
C14

R25

V22

V18

R24

R29

X11/15

X10

C16

V23

X11/14

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.

The rectifier diodes are in short

circuit.

Faulty control card A001.

Relay K1

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.

Faulty power adjustment

potentiometer R001.

Check the potentiometer condition

(R001 = 10 k)

Faulty control card A001.

Change control card A001.

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.

Welding current cant be adjusted

by potentiometer R001.

Main circuit diagrams

Minarc 150/150 VRD

Minarc 151
8

Block diagram

A001

Z001

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

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)

X22

X21

X15
X14

X16 X17

X18
X19

X20

X9
X13

X8

X7
X11
X12

X10
X6

X1
X5

X3

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

Secondary rectifier

Smoothing capacitors

X10

X11

EMI

Primary rectifier
X1, X3

EMI, DC-link charging

LZ101

X5

22

Control card A001 layout

N1
Voltage regulator
(+ 20 V)

X1
S1

N2
PWM-circuit

MMA/TIG

R26
Max. current
adjustment

N3
Comparator

R35
Min. current
adjustment

R49

H2

Current adjustment

ON / VRD ON

H1

N4

Overheat
protection

Comparator

23

Structure

A001

Z001

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)!!

E2/2

C2E1/1

B2/6

Discrete-IGBTs tightening torque to the heatsink is 0,61,2 Nm!

C1/3

B1/4

TR 2

IGBT-TESTER

TR 1

ON

CONTROL

OFF

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