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• Simpalean Nicolae

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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 105 0,5

~ + 320 V

Max.

V1

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 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

U

C20

V24

V26, V27

R35

R37

V25

T001

U

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.

5

Main circuit C21

R34

V28, V29 L001

X003

X6

R20

R21

X7

V26

R33

U

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.

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;

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 kΩ)

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 can´t be adjusted by potentiometer R001.

7

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

9

Operational tests / measurings

C

F

B

E

A

D

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

C

B

A B C D E

A

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 (+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 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 (10Ω)!!

G

C

E

E2/2

C2E1/1

B2/6

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