Kemppi Minarc 150 User manual

150150
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............……………………………
……………..……………..
33
44
4 - 64 - 6
77
88
99
1010
10, 1110, 11
1212
1313
1414
1515
1616
1616
1717
1818
1919
2020
2020
2121
2222
2323
24, 2524, 25
2626
2626
2727

Technical data
S
u
p
p
l
y
v
o
l
t
a
g
e
,
1
~
5
0
/
6
0
H
z
2
3
0
V
±
1
5
%
2
3
0
V
±
1
5
%
1
1
0
V
±
1
5
%
Loadability
3
5
%
E
D
(
M
M
A
)
1
4
0
A
(
7
,
5
k
V
A
)
1
4
0
A
(
7
,
5
k
V
A
)
1
4
0
A
(
7
,
5
k
V
A
)
1
0
0
%
E
D
(
M
M
A
)
1
0
0
A
(
5
,
1
k
V
A
)
1
0
0
A
(
5
,
1
k
V
A
)
1
0
0
A
(
5
,
1
k
V
A
)
3
5
%
E
D
(
T
I
G
)
1
5
0
A
(
5
,
0
k
V
A
)
1
5
0
A
(
5
,
0
k
V
A
)
1
5
0
A
(
5
,
0
k
V
A
)
1
0
0
%
E
D
(
T
I
G
)
1
1
0
A
(
3
,
3
k
V
A
)
1
1
0
A
(
3
,
3
k
V
A
)
1
1
0
A
(
3
,
3
k
V
A
)
S
u
p
p
l
y
c
a
b
l
e
/
f
u
s
e
s
2
,
5
m
m
² S
/
3
,
3
m
1
6
A
2
,
5
m
m
² S
/
3
,
3
m
1
6
A
6
m
m
² S
/
2
,
0
m
3
2
A
We
ld
in
g cu
rr
en
t ra
ng
e (M
MA
)
10 A
/ 2
0,
5 V…
14
0 A /
25
,6
V
10 A
/ 2
0,
5 V…
14
0 A /
25
,6 V
10 A
/ 2
0,
5 V…
14
0 A /
25
,6
V
S
u
i
t
a
b
l
e
s
t
i
c
k
s
i
z
e
s
ø
1
,
5
…
3
,
2
5
m
m
ø
1
,
5
…
3
,
2
5
m
m
ø
1
,
5
…
3
,
2
5
m
m
W
e
l
d
i
n
g
p
o
w
e
r
a
d
j
.
S
t
e
p
l
e
s
s
S
t
e
p
l
e
s
s
S
t
e
p
l
e
s
s
O
C
V
~
+
8
5
V
~
+
3
0
V
~
+
8
5
V
I
d
l
i
n
g
p
o
w
e
r
<
1
0
W
<
1
0
W
<
1
0
W
E
f
f
i
c
i
e
n
c
y
0
,
8
0
,
8
0
,
8
P
o
w
e
r
f
a
c
t
o
r
0
,
6
0
(
1
4
0
A
/
2
5
.
5
V
)
0
,
6
0
(
1
4
0
A
/
2
5
.
5
V
)
0
,
6
0
(
1
4
0
A
/
2
5
.
5
V
)
T
e
m
p
e
r
a
t
u
r
e
c
l
a
s
s
B
(
1
3
0
°
C
)
/
H
(
1
8
0
°
C
)
B
(
1
3
0
°
C
)
/
H
(
1
8
0
°
C
)
B
(
1
3
0
°
C
)
/
H
(
1
8
0
°
C
)
O
p
e
r
a
t
i
o
n
t
e
m
p
e
r
a
t
u
r
e
r
a
n
g
e
-
2
0
…
+
4
0
°
C
-
2
0
…
+
4
0
°
C
-
2
0
…
+
4
0
°
C
S
t
o
c
k
t
e
m
p
e
r
a
t
u
r
e
r
a
n
g
e
-
4
0
…
+
6
0
°
C
-
4
0
…
+
6
0
°
C
-
4
0
…
+
6
0
°
C
C
a
s
i
n
g
c
l
a
s
s
I
P
2
3
C
I
P
2
3
C
I
P
2
3
C
N
o
r
m
s
I
E
C
6
0
9
7
4
-
1
,
-
1
0
I
E
C
6
0
9
7
4
-
1
,
-
1
0
I
E
C
6
0
9
7
4
-
1
E
N
5
0
1
9
9
E
N
5
0
1
9
9
E
N
5
0
1
9
9
Dimensions
L
e
n
g
t
h
3
2
0
m
m
3
2
0
m
m
3
2
0
m
m
W
i
d
t
h
1
2
3
m
m
1
2
3
m
m
1
2
3
m
m
H
e
i
g
h
t
2
6
5
m
m
2
6
5
m
m
2
6
5
m
m
W
e
i
g
h
t
4
,
0
(
4
,
6
)
k
g
4
,
0
(
4
,
6
)
k
g
4
,
4
(
5
,
2
)
k
g
M
i
n
a
r
c
1
5
0
M
i
n
a
r
c
1
5
0
VRD
Minarc 151
3

Operation principle
VDC
t
105
13µs
M
a
x
.
0
,
5
~ + 320 V
1/3
V1
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
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.
+
t
+
t
X5
X1
X3
R
3
1
R
3
2
L2
C
9
C
5
C
1
0
L1
R
3
0
R
2
3
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, Minarc 150/150 VRD.
4

Main circuit
Secondary circuit connection, Minarc 150/151.
T
0
0
1
U
R35
U
V28, V29
C21
R34
R
3
7
C
2
0
V
2
6
,
V
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
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.

T
0
0
1
U
R35
U
V28, V29
C21
R34
R
3
7
C
2
0
V
2
6
,
V
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

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.
D
I
S
T
U
R
B
A
N
C
E
P
O
S
S
I
B
L
E
C
A
U
S
E
R
E
M
E
D
Y
Power source doesn´t start; OCV
~ 0 V;
C
o
o
l
i
n
g
f
a
n
M
0
0
1
D
i
s
c
o
n
n
e
c
t
t
h
e
f
a
n
c
o
n
n
e
c
t
o
r
X
2
0
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.
F
a
u
l
ty
c
o
n
t
ro
l
c
a
r
d
A
0
0
1
.
C
h
a
n
g
e
t
h
e
c
on
t
ro
l
c
a
r
d
A
0
0
1
.
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.
R
e
l
a
y
K
1
C
h
e
c
k
t
h
e
r
e
l
a
y
o
p
e
r
a
t
i
o
n
.
Welding current can´t be adjusted
by potentiometer R001.
Faulty power adjustment
potentiometer R001.
Check the potentiometer condition
(R001 = 10 k
Ω
)
F
a
u
l
ty
c
o
n
t
r
o
l c
a
r
d A
0
0
1
.
C
h
a
n
g
e c
o
n
t
r
o
l c
a
r
d A
0
0
1
.
Troubleshooting diagram
7

Main circuit diagrams
8
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
16
9
Z002
Relaycard
4
Minarc 151

Operational tests / measurings
A
B
C
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
E
D
F
10