Kemppi Oy
SERVICE MANUAL
MinarcTig Evo 200
Страница 1: ...Kemppi Oy SERVICE MANUAL MinarcTig Evo 200 ...
Страница 2: ...ard 11 3 4 3 A002 spark card 12 3 4 4 P001 panel card 12 3 4 5 Setup parameters 13 3 4 6 Error codes 14 4 SERVICE INSTRUCTIONS 15 4 1 Programming 15 4 2 Measurements and tests 15 4 2 1 Z001 Main circuit card 15 4 2 1 1 Input rectifier and PFC circuit 15 4 2 1 2 IGBT 18 4 2 1 3 Secondary rectifier 19 4 2 1 4 Voltages 19 4 2 1 5 Overheat protection 20 4 2 2 A001 control card 22 4 2 3 Cooling fan 22 ...
Страница 3: ...le it is turned off but it is always better to ensure this by measuring the voltage Wait at least one minute for the capacitors to become discharged Digital multimeters later DMM may give different values depending the specifications they have For ex ample diode measuring values may vary between the DMM models In this manual Fluke 179 DMM is used This machine has all the control circuits in the pr...
Страница 4: ...side to meet the latest European regulations The MinarcTig Evo machines are for DC TIG and MMA welding MinarcTig Evo 200 can be connected to the mains supply of 230VAC 1 PFC makes possible to weld with the full power TIG 200A even when modern circuit breakers are used MinarcTig Evo panel card software can be reprogrammed in the field with Datamaster 2 Overvoltage watch is 290VAC and under voltage ...
Страница 5: ... ED 140 A 15 6 V MMA 35 ED 170 A 26 8 V 100 ED 110 A 24 4 V Welding range TIG 5 A 10 2 V 200 A 18 V MMA 10A 20 4 V 170 A 26 8 V No load voltage peak 95 V VRD 30V Idle power TIG 10 W MMA 30 W Power factor at 100 ED TIG 0 98 MMA 0 98 Efficiency at 100 ED TIG 76 MMA 82 Arc striking voltage 6 12kV MMA welding electrodes MMA Ø 1 5mm 4 mm External dimensions LxWxH Height with handle 449x210x358 mm Weigh...
Страница 6: ...Service manual MinarcTig Evo 200 Version 1 1 5 29 9 2015 4 Kemppi Oy 3 2 Wiring diagrams ...
Страница 7: ...truction Left side Front Right side Back Left side side plate removed Left side plate is installed with T20 4 pieces torx screws and side plate has to be removed before opening case Case itself is kept in place with T15 12 pieces torx screws Places marked in picture on the left ...
Страница 8: ...in switch 2 Primary heat sink 3 T001 main transformer 4 Secondary heat sink 5 Spark transformer 6 Remote control socket 7 P001 panel card 8 A001 control card 9 Secondary choke 10 Z001 main circuit card 11 Y001 magnetic valve 12 M001 fan 13 T002 Auxiliary transformer 1 2 3 4 5 8 6 10 9 7 11 12 13 ...
Страница 9: ...acitors 4 Main transformer 5 Secondary diodes zero side 6 Work return connection 7 Positive output connection 8 Secondary diodes positive side 9 Flat cable to A001 card 10 Secondary choke input connection 11 Secondary choke output connection 12 PFC choke 12 11 10 Note that primary and secondary heat sinks and secondary choke are not in the picture BUT they are still part of the Z001 card ...
Страница 10: ...A002 control card 2 Shunt connection to the A001 card X8 brown X7 black 3 X5 Remote control connector 4 X1 connector to P001 panel card 5 X6 connector to TIG torch control line 6 Filter choke for TIG remote connection 7 X3 connector to auxiliary transformer 8 X1 flat cable connector from P001 to A001 card 1 3 4 5 6 7 2 8 ...
Страница 11: ...cture 1 X3 Spark transformer connector output 2 X1 Main transformer secondary connector input 3 X2 Control card connector Spark ON OFF 1 3 2 1 1 X10 Service connector for Datamaster 2 2 7 Segment display 3 X2 membrane panel connector 4 X1 control card flat cable connection 5 Panel microprocessor 6 Pulse potentiometer 3 6 2 5 4 ...
Страница 12: ...ns wire and secondary 3 foil The transformer has a 160 C PTC for over heat protection While temperature rises the resistance stays under 100Ω until the breakdown point then the PTC goes to high resistance mode 10kΩ Control logic stops the inverter if the resistance value rises over 1 5kΩ Secondary choke L4 inductance is 5μH and its winding has 10 turns The choke slows the secondary voltage changes...
Страница 13: ... in the DC link and feedback goes to the A001 card Secondary rectifier has two working and four demagnetizing diode packages Each package holds two diodes so total quantity is double Cooling fan control circuit Control signal comes from the P001 card Note that cool ing fan uses 24VDC that is in the primary side Dual forward inverter gate driver circuit Control signal is coming from the A001 card S...
Страница 14: ...and does not need to be re adjusted in service A002 card is controlled by P001 panel card 3 4 4 P001 panel card Microprocessor has many different operations o Controls panel LEDs and 7 segment display o Reads membrane switches and pulse potentiometer o Reads remote controller and TIG torch control signals via A001 o Controls cooling fan gas valve spark ignition and PFC operations o Reads over and ...
Страница 15: ...of the torch switch 0 current can be sloped down and up again d 3 Minilog SearcArc 2 4T LOG Minilog 1 Minilog 0 4T LOG E Current Level at ignition with upslope 5 40 Range 20 Factory default F 1 Factory settings recall 0 Factory default h Pregas time minimum 0 0 2 0 s Range 0 0 s Factory default J Postgas time minimum 0 10 s Range 1 s Factory default L Pregas time maximum 5 20 s Range 10 s Factory ...
Страница 16: ...code Explanation E 2 Supply voltage is too low E 3 Supply voltage is too high E 4 Main transformer overheated E 6 Secondary voltage too high safety limit 113 V E 13 Panel card and control card versions do not match One of them is AU version and another one non AU version E 40 IGBT NTC overheated ...
Страница 17: ...o panel X10 Switch on the MinarcTig and start updating and wait until downloading is completed Once it is finished DM2 can be disconnected and the new software is ready to be used Software version can be checked by switching on the machine and then pressing one of the panel buttons 7 Segment display shows the software version See more DM2 information in the user manual 4 2 Measurements and tests 4...
Страница 18: ...meter diode function to measure their threshold voltage Diodes must be measured both forward bias and reverse bias condition to make sure they are fine See following pictures and tables to make sure all the measurements are done L1 L2 Discharge diode Series diode GND L1 L2 Rectifier output 1 3 2 4 L1 L2 ...
Страница 19: ...VDC Diode 2 forward bias L2 Rectifier output 0 2 0 7VDC Diode 4 reverse bias L2 GND No value Diode 2 reverse bias Rectifier output L2 No value Diode 4 forward bias GND L2 0 2 0 7VDC Diode Positive test lead Negative test lead Result Series diode forward bias PFC input DC link positive 0 4 0 9VDC Discharge diode reverse bias PFC input GND No value Series diodes reverse bias DC link positive PFC inp...
Страница 20: ...tion IGBT1 emitter IGBT 2 collector DC link positive 0 2 0 7VDC IGBT 2 diode lower separate di ode reverse bias condition IGBT1 emitter IGBT 2 collector GND No value IGBT 1 diode upper separate diode reverse bias condition DC link positive IGBT1 emitter IGBT 2 collector No value IGBT 2 diode lower separate di ode forward bias condition GND IGBT1 emitter IGBT 2 collector 0 2 0 7VDC If the transform...
Страница 21: ...e test lead Result Forward bias Negative output terminal Positive output terminal 0 2 0 6VDC Reverse bias Positive output terminal Negative output terminal No value 4 2 1 4 Voltages The Z001 main circuit card has the DC link voltage after the input rectifier and several auxiliary voltages made by the auxiliary PSU Note These voltages are in the primary side Even touching the ground level may affec...
Страница 22: ...an 100Ω In over temperature situation PTC goes to high resistance mode 10kΩ Machine gives temperature alarm at 1 5kΩ A broken PTC has usually hundreds of kilo ohms resistance or no value at all Note that the PTC signal is only delivered onto the Z001 the control logic is on the A001 control card Primary GND TP5 390VDC DC link TP4 Measuring points for PTC 160 o C is X15 and X16 Value in 22 o C is 7...
Страница 23: ...re the resistance it should be between 14 2 8kΩ in a cool machine in environ ment temperature 0 40 C While temperature rises resistance lowers and at 500Ω point the inverter stops and gives overheat alert A broken NTC has usually hundreds of kilo ohms resistance no value at all or short cir cuit GND IGBT module NTC resistor ...
Страница 24: ...o possibility to do low voltage test for this machine 4 2 5 Safety tests Safety tests are made normally Note that PE conductivity test point and chassis ground test point is in gas valve snap connector 4 3 Semiconductor installation It is a must to use torque screwdriver while tightening any power components onto the heat sink See following sections for tightening torques 4 3 1 Rectifier PFC modul...
Страница 25: ...ule onto the PCB with the plastic caps instead of the component soldered legs The torx screws with caps can be tightened only up to 0 5 Nm or otherwise the PCB may bend 4 3 2 Secondary rectifier Heat sink transfer should be spread in an even layer onto the heat sink Then card should be immediately mounted onto the heat sink This minimizes the possibility of any contamination dirt etc getting betwe...
Страница 26: ...Service manual MinarcTig Evo 200 Version 1 1 5 29 9 2015 24 Kemppi Oy 5 NOTES ...
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