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 mm² S / 3,3 m 16 A 2,5 mm² S / 3,3 m 16 A 6 mm² S / 2,0 m 32 A
Welding 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 V
Suitable stick sizes ø 1,5…3,25 mm ø 1,5…3,25 mm ø 1,5…3,25 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 (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, -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

3
Operation principle

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.

VDC
~ + 320 V 105

0,5
V1

Max.
t
1/3
13µs

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
R9
X11/12
V16

V4, V5, V6
C13

X1
V20

X13
R31

L2 L1
V21

V7, V3

T001
C2, C3, C4
R32

C15

V11
C5

C9

+t +t
X3 X12
V1, V2

R30 R23
C10

T2
V8, V9, V10

K1
X5

Primary circuit connection, Minarc 150/150 VRD.

4
Main circuit

X11/7
R14 R17 R13 R8

R9
X11/12

V16

V3, V4, V5
C11
X1
X13
X2

C2, C3
L1 L2

V6, V2

T001
R24

C16

V10

C9
X3 X12

V1, V11
X4

C10

C4, C5

T2
X5

V7, V8, V9
Primary circuit connection, Minarc 151.

C21
R34

V28, V29

L001
X7 X003

X6
R21

R20

U
R37
T001

R35
V26, V27
V25

R33
U

V24
C20
V26

X8
X11/11 X9 X004
V19

R11 V30
V28

V22
X11/14 X10
V23

C16

X21
X11/15
C14

C17

C19

R27

R36
R29

R24

V18
R25
V22

X22
C18
X5

Secondary circuit connection, Minarc 150/151.

5
Main circuit
C21
R34

V28, V29

L001
X7 X003

X6

R21

R20
U

R37
T001
R35

V26, V27
V25

R33
U
V24

C20
V26
X8
X11/11 X9 X004
V19

R11 V30
V28

V22
X11/14 X10
V23

C16
X21
X11/15

C14

C17

C19

R27

R36
R29

R24
V18

R25
V22

X22
C18
X5

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.
Troubleshooting diagram
DISTURBANCE
Power source doesn´t start; OCV
~ 0 V;
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 can´t be adjusted
by potentiometer R001.
POSSIBLE CAUSE
Cooling fan M001
The rectifier diodes are in short
circuit.
Faulty primary circuit power
semiconductor.
Faulty control card A001.
Relay K1
Faulty power adjustment
potentiometer R001.
Faulty control card A001.
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.
Check the potentiometer condition
(R001 = 10 kΩ)
Change control card A001.
7
Main circuit diagrams

Minarc 150/150 VRD

Minarc 151

8
Block diagram

A001 Z001

Controller (PWM) Power stage

Gate buffer EMI-filter
Set value circuit 16 DC-link charging
Voltage watch Aux. voltages
MMA ignition Voltage reserve circuit
MMA dynamics OCV controller
Temperature control Overvoltage protection
Supply voltage watch
Auxiliary voltage watch
TIG-locking
TIG-scaling

Z002

Relaycard

Minarc 151

9
Operational tests / measurings

C F

B
E

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)

D E

A
B

A Main transformer T001 primary

B Main transformer T001 secondary
C After the rectifier
D Main transformer auxiliary coil
E 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

X1/1 GND
X1/2 Current info from primary
X1/3 GND
X1/4 Gate control, upper IGBTs
G X1/5 Gate control, lower IGBTs
X1/6 GND
X1/7 Supply voltage watch
H X1/8 Temperature watch (PTC:t)
X1/9 GND
I X1/10 Auxiliary voltage (+20…30 V)
X1/11 Signal lamp H2 control / VRD
X1/12 Auxiliary voltage from DC-link
J X1/13 GND
X1/14 Auxiliary voltage +20 V
X1/15 OCV control (~ +85 V)
X1/16 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)

X15 X16 X17 X18 X20

X21
X22 X14 X19

X9

X8 X13

X7
X11
X10 X12
X6

X1

X3 X5

X1, X3 Supply voltage

X5 Protective earth
X6, X8 Main transformer T001 sec.
X7 Sec. Choke L001 (+)
X9 X004 (-)
X10 X003 (+)
X11 Connection, A001
X12, X13 Main transformer T001 primary
X14, X15 Main transformer T001 auxiliary
coil
X16, X17 PTC RT101
X18, X19 PTC RZ101
X20/1, 2 Fan M001
X21 X003 (+) 21
X22 X004 (-)
Main circuit card Z001 layout (Minarc 150)

Main transformer

X10
Smoothing capacitors

Secondary rectifier
X11

EMI

Primary rectifier

EMI, DC-link charging X1, X3

LZ101 X5

22
Control card A001 layout

N1
Voltage regulator
(+ 20 V)
X1
N2
PWM-circuit
S1
MMA/TIG

R26
Max. current N3
adjustment Comparator
R35
Min. current
adjustment R49
H2 Current adjustment
ON / VRD ON
H1 N4
Overheat Comparator
protection

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, G C E

plus the gate resistors (10Ω)!!

Discrete-IGBT´s tightening torque to the heatsink is 0,6…1,2 Nm!

C2E1/1

E2/2
B2/6
C1/3

B1/4

IGBT-TESTER
TR 1
OFF

CONTROL
ON

TR 2
Secondary diode testing

When testing secondary diodes the other coil end of the main
transformer (T001) must be disconnected. Main transformer
cable 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