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Kemppi Minarc 150, Service Manual

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Kemppi Minarc 150 Service Manual Download Page 17

X1/1

GND

X1/2

Current  info  from  primary

X1/3

GND

X1/4

Gate  control,  upper  IGBTs

X1/5

Gate  control,  lower  IGBTs

X1/6

GND

X1/7

Supply  voltage  watch

X1/8

Temperature  watch  (PTC:t)

X1/9

GND

X1/10

Auxiliary voltage (+20…30 V)

X1/11

Signal lamp H2 control / VRD

X1/12

Auxiliary voltage from DC-link

X1/13

GND

X1/14

Auxiliary  voltage  +20  V

X1/15

OCV  control  (~  +85  V)

X1/16

GND

G

H

I

J

Measuring point on the flat cable

17

Summary of Contents for Minarc 150

Page 1: ...150 150 150 150 VRD VRD 151 151 Service Manual Service Manual Ver 1 1 Ver 1 1 ...

Page 2: ... 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 ci...

Page 3: ...tick 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 Ca...

Page 4: ...e 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 t t X5 X1 X3 R 3 1 R 3 2 L2 C 9 C 5 C 1 0 L1 R30 R23 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 0 1 T 2 K1 X11 12 V 1 6 C 1 3 R9 X13 X12 Primary circuit connection M...

Page 5: ...5 V 2 6 V24 R 2 1 V19 R11 X11 11 X11 14 X11 15 V18 V 2 3 V 2 2 C18 R 2 9 R 2 4 R 2 5 C 1 6 V30 V28 V22 C 1 4 C 1 7 X5 C 1 9 R 2 7 R 3 6 X10 X21 X22 5 X5 X2 X3 R 2 4 L1 C 9 C 1 0 L2 C 1 6 V10 C 2 C 3 V 6 V 2 V 1 V 1 1 V 3 V 4 V 5 V 7 V 8 V 9 T 0 0 1 T 2 X11 12 V 1 6 C 1 1 R9 X13 X12 X1 X4 R8 R13 R17 R14 C 4 C 5 X 1 1 7 Primary circuit connection Minarc 151 ...

Page 6: ...2 7 R 3 3 X7 X9 L001 X003 X004 X6 X8 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 2 C18 R 2 9 R 2 4 R 2 5 C 1 6 V30 V28 V22 C 1 4 C 1 7 X5 C 1 9 R 2 7 R 3 6 X10 X21 X22 Main circuit Secondary circuit connection Minarc 150 VRD 6 ...

Page 7: ... 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 Faulty control card A001 Change the control card A001 The power source starts and the OCV rises up to 85 V after which the power sou...

Page 8: ...Main circuit diagrams 8 Minarc 150 150 VRD Minarc 151 ...

Page 9: ...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 16 9 Z002 Relaycard 4 Minarc 151 ...

Page 10: ...ain 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 E D F 10 ...

Page 11: ...A Main transformer T001 primary B Main transformer T001 secondary C After the rectifier D Main transformer auxiliary coil E Fan M001 A B C D E Measuring points on main circuit card Z001 Minarc 150 11 ...

Page 12: ...Measuring point A Main transformer T001 primary voltage Main transformer T001 primary voltage min MMA Main transformer T001 primary voltage max MMA 12 ...

Page 13: ...Measuring point B Main transformer T001 secondary voltage Main transformer T001 secondary voltage min MMA Main transformer T001 secondary voltage max MMA 13 ...

Page 14: ...Measuring point C Voltage after secondary rectifier Voltage after secondary rectifier min MMA Voltage after secondary rectifier max puikko 14 ...

Page 15: ...Measuring point D Auxiliary coil voltage Auxiliary coil voltage min MMA Auxiliary coil voltage max MMA 15 ...

Page 16: ...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 ...

Page 17: ...wer IGBTs X1 6 GND X1 7 Supply voltage watch X1 8 Temperature watch PTC t X1 9 GND X1 10 Auxiliary voltage 20 30 V X1 11 Signal lamp H2 control VRD X1 12 Auxiliary voltage from DC link X1 13 GND X1 14 Auxiliary voltage 20 V X1 15 OCV control 85 V X1 16 GND G H I J Measuring point on the flat cable 17 ...

Page 18: ...Measuring point G Gate control upper IGBTs Gate pulse min MMA Gate pulse max MMA 18 ...

Page 19: ...Measuring point H Gate control lower IGBTs Gate pulse min MMA Gate pulse max MMA 19 ...

Page 20: ...Measuring point I Auxiliary voltage from DC link Measuring point J Signal lamp H2 control VRD ON 20 ...

Page 21: ...10 X11 X5 X21 X22 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 X22 X004 21 ...

Page 22: ...Main circuit card Z001 layout Minarc 150 S m o o t h i n g c a p a c i t o r s EMI Primary rectifier EMI DC link charging X5 LZ101 X1 X3 X11 S e c o n d a r y r e c t i f i e r X10 Main transformer 22 ...

Page 23: ...rent adjustment R35 Min current adjustment Control card A001 layout R49 Current adjustment X1 S1 MMA TIG H2 ON VRD ON H1 Overheat protection N1 Voltage regulator 20 V N2 PWM circuit N3 Comparator N4 Comparator 23 ...

Page 24: ...Structure Z001 A001 T10 T15 T25 3 mm 24 ...

Page 25: ...Structure Extracting the control card A001 25 ...

Page 26: ... IGBT s tightening torque to the heatsink is 0 6 1 2 Nm 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 ca...

Page 27: ...Notes 27 ...

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