Kemppi Minarc 150 User manual

150150

VRDVRD

151151

Service ManualService Manual

Ver. 1.1Ver. 1.1

ContentsContents

Technical Technical

data………………………….…………data………………………….…………

…...…...

Operation Operation

principle…………………………………principle…………………………………

….….

Main Main

circuit……………………………circuit……………………………

……….……...……….……...

Troubleshooting diagram………………………...……Troubleshooting diagram………………………...……

Main ciruit Main ciruit

diagrams…………………………diagrams…………………………

……….……….

Block Block

diagram……………………………diagram……………………………

…….……..…….……..

Operational tests / measurings…………...........……...Operational tests / measurings…………...........……...

Measurings...……………………...…..Measurings...……………………...…..

Main transformer T001 prim. voltage...Main transformer T001 prim. voltage...

Main transformer T001 sec. voltage.....Main transformer T001 sec. voltage.....

Voltage after sec. rectifier..............…...Voltage after sec. rectifier..............…...

Auxiliary coil voltage..………………..Auxiliary coil voltage..………………..

Fan M001 voltage..........………………Fan M001 voltage..........………………

Pole voltage in OCV........…………….Pole voltage in OCV........…………….

Measuring points in the flat cable..…...Measuring points in the flat cable..…...

Gate control, upper IGBTs.…………...Gate control, upper IGBTs.…………...

Gate control, lower IGBTs.…………...Gate control, lower IGBTs.…………...

Aux. voltage in DC-link..………….….Aux. voltage in DC-link..………….….

Signal lamp H2 control / VRD ON..….Signal lamp H2 control / VRD ON..….

Main circuit card Z001 connectors.…………………...Main circuit card Z001 connectors.…………………...

Main circuit card Z001 layout…..……………………..Main circuit card Z001 layout…..……………………..

Control card A001 Control card A001

layout.……………………………layout.……………………………

....

Structure………………………………………………..Structure………………………………………………..

IGBT-transistor testing..............……………………….IGBT-transistor testing..............……………………….

Sec. diode Sec. diode

testing.............……………………………..testing.............……………………………..

Notes............……………………………Notes............……………………………

……………..……………..

4 - 64 - 6

1010

10, 1110, 11

1212

1313

1414

1515

1616

1717

1818

1919

2020

2121

2222

2323

24, 2524, 25

2626

2727

Technical data

Loadability

(

)

(

)

(

)

(

)

(

)

(

)

(

)

(

)

(

)

(

)

(

)

(

)

(

)

(

)

(

)

(

)

² S

g cu

t ra

e (M

)

10 A

/ 2

5 V…

0 A /

10 A

/ 2

5 V…

0 A /

,6 V

10 A

/ 2

5 V…

0 A /

…

(

)

(

)

(

)

(

)

(

)

(

)

(

)

(

)

(

)

…

Dimensions

(

)

(

)

(

)

VRD

Minarc 151

Operation principle

VDC

105

13µs

M

a

x

.

0

,

5

~ + 320 V

1/3

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.

R

3

1

R

3

2

C

9

C

5

C

1

0

C

1

5

V

2

1

V

2

0

V11

C

2

,

C

3

,

C

4

V

7

,

V

3

V

1

,

V

2

V

4

,

V

5

,

V

6

V

8

,

V

9

,

V

1

0

T

0

1

T

2

X11/12

V

1

6

C

1

3

X13

X12

Primary circuit connection, Minarc 150/150 VRD.

Main circuit

Secondary circuit connection, Minarc 150/151.

T

0

1

R35

U

V28, V29

C21

R34

R

3

7

C

2

0

V

2

6

,

V

2

7

R

3

L001

X003

X004

R

2

0

V

2

5

V

2

6

V24

R

2

1

V19

R11

X11/11

X11/14

X11/15

V18

V

2

3

V

2

C18

R

2

9

R

2

4

R

2

5

C

1

6

V30

V28

V22

C

1

4

C

1

7

C

1

9

R

2

7

R

3

6

X10

X21

X22

R

2

4

C

9

C

1

0

C

1

6

V10

C

2

,

C

3

V

6

,

V

2

V

1

,

V

1

V

3

,

V

4

,

V

5

V

7

,

V

8

,

V

9

T

0

1

T

2

X11/12

V

1

6

C

1

X13

X12

R13

R17

R14

C

4

,

C

5

1

/

7

Primary circuit connection, Minarc 151.

T

0

1

R35

U

V28, V29

C21

R34

R

3

7

C

2

0

V

2

6

,

V

2

7

R

3

L001

X003

X004

R

2

0

V

2

5

V

2

6

V24

R

2

1

V19

R11

X11/11

X11/14

X11/15

V18

V

2

3

V

2

C18

R

2

9

R

2

4

R

2

5

C

1

6

V30

V28

V22

C

1

4

C

1

7

C

1

9

R

2

7

R

3

6

X10

X21

X22

Main circuit

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.

Power source doesn´t start; OCV

~ 0 V;

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.

Check the secondary diodes

condition and change if needed. See

the changing of secondary diodes,

page 26.

Faulty primary circuit power

semiconductor.

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.

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.

Faulty power adjustment

potentiometer R001.

Check the potentiometer condition

(R001 = 10 k

Ω

)

l c

d A

e c

l c

d A

Troubleshooting diagram

Main circuit diagrams

Minarc 150/150 VRD

Minarc 151

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

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

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