Kemppi MinarcTig Evo 200 User manual

Kemppi Oy
SERVICE MANUAL
MinarcTig Evo 200

Kemppi Oy
CONTENTS
1. READ THIS FIRST........................................................................................................................................... 1
2. GENERAL......................................................................................................................................................... 2
3. TECHNICAL INFORMATION........................................................................................................................... 3
3.1. Technical data........................................................................................................................................... 3
3.2. Wiring diagrams ........................................................................................................................................ 4
3.3. Construction.............................................................................................................................................. 5
3.3.1. Inner structure.................................................................................................................................... 6
3.3.2. Z001 main circuit card structure ........................................................................................................ 7
3.3.3. A001 control card structure................................................................................................................ 8
3.3.4. A002 spark card structure.................................................................................................................. 9
3.3.5. P001 panel card structure.................................................................................................................. 9
3.4. Description of operation.......................................................................................................................... 10
3.4.1. Z001 Main circuit card ..................................................................................................................... 10
3.4.2. A001 Control card............................................................................................................................ 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
4.2.4. Low voltage tests............................................................................................................................. 22
4.2.5. Safety tests...................................................................................................................................... 22
4.3. Semiconductor installation...................................................................................................................... 22
4.3.1. Rectifier/PFC module and IGBT ...................................................................................................... 22
4.3.2. Secondary rectifier........................................................................................................................... 23
4.4. Final testing............................................................................................................................................. 23
5. NOTES ........................................................................................................................................................... 24
APPENDIX.......................................................................................................................................................... 24

Service manual MinarcTig Evo 200
Version 1.1.5.
29.9.2015
1
Kemppi Oy
1. READ THIS FIRST
230VAC 50/60Hz and 390VDC or higher are inside the machine
Before removing any covers or commencing any testing or measurement disconnect the power source
from the mains voltage
Dangerous DC voltage may still exist after the removal of the input voltage. Machine discharges the volt-
age while 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 primary side and special attention must be considered
while working with the internal parts.
The device may be repaired only by a person legally authorized to perform electric work.

Service manual MinarcTig Evo 200
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2. GENERAL
MinarcTig Evo is a new generation small TIG and MMA machine. It is based on MinarcTig 180, but the
power section and design are totally new. Machine has power factor correction in the primary 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 watch is 150VAC.
Current range is 5-200A in TIG and 10-170A in MMA mode.

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3. TECHNICAL INFORMATION
3.1. Technical data
MinarcTig Evo 200
Connection voltage
1~50/60 Hz
230V ± 15%
Rated power
25 % ED TIG
200 A/4.5 kVA
35 % ED MMA
170 A/ 5.8 kVA
Supply current, I
max1
TIG
19.8 A
MMA
25.3 A
Supply current, I
eff1
TIG
12.1 A
MMA
15.0 A
Connection cable
HO7RN-F
3G1.5 (1.5mm
2
, 3m)
Fuse
Type C
16A
Duty cycle 40° C
TIG
35 % ED 200 A/18 V
100 % 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
Weight
11 kg (without cable)
Temperature class
F (155º C)
EMC class
A
Degree of protection
IP23S
Operating temperature range
-20…+40º C
Storage temperature range
-40…+60º C
Standards
IEC60974-1
IEC60974-3
IEC60974-10
IEC61000-3-12

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3.2. Wiring diagrams

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3.3. Construction
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.

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3.3.1. Inner structure
1. Main 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.

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3.3.2. Z001 main circuit card structure
1.
2.
3.
4.
5.
6.
7.
9.
8.
1. Primary rectifier and PFC module
2. IGBT module
3. DC-link capacitors
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.

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3.3.3. A001 control card structure
1. X2 connector to 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.

Service manual MinarcTig Evo 200
Version 1.1.5.
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3.3.4. A002 spark card structure
3.3.5. P001 panel card structure
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.

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3.4. Description of operation
MinarcTig Evo has the following parts and components:
Main circuit card Z001
Control card A001
Spark card A002
Panel card P001
Main switch S001
EMC choke L001
Auxiliary transformer T002
Spark transformer T003
Cooling fan M001
Shunt R001
Gas valve Y001
TIG torch control connector X001
Remote control connector X002
Main output terminals (Dix connectors) X003 and X004
TIG torch connector X005

Cooling fan is in the back of the machine and fresh air intake is through the rear grill. Air flows through the
heat sinks and exits in the front of the machine.
Note that both Z001 and A001 cards have +24VDC, but they are in different potential, Z001 in primary
and A001 in secondary.
3.4.1. Z001 Main circuit card
Main circuit card coil components and their functions:
Main transformers transformer ratio is 3,67:1; its primary winding is 11 turns (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 and works as energy storage in the deep short
circuits.
PFC choke works together with PFC circuit. It has 66 turns.
Main circuit card itself provides the following functions:
DC-link soft start charging and over voltage disconnecting circuit. It avoids full power
connection if primary has short circuit or main supply voltage rises over the safety
limit. Relay control is in A001 card.
EMC filtering circuit filters EMC disturbances from main supply voltage to the ma-
chine and vice versa.
The single-phase rectifier/PFC module rectifies the mains voltage (nominal 230VAC)
to PFC circuit, approx nominal value of 320VDC. Rectifier holds four power diodes.
PFC circuit is integrated in the same module with rectifier diodes. PFC circuit (IGBT,

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diode and PFC choke) keeps the primary currents and voltage in the same phase.
This rises the power factor up to 0,98. PFC is boost type and raises the DC-link volt-
age up to 390VDC.
Power section is based on dual forward architecture with 60 kHz switching frequency.
IGBTs have two stages: ON/conducting and OFF/demagnetizing. OFF-stage must
last longer comparing to ON-stage because main transformer needs to be demagnet-
ized or otherwise it goes to saturation.
IGBT module has integrated NTC resistor for over heat protection: In 0-40° C envi-
ronment temperature range resistance varies between 14-2,8kΩ if the machine is
cool (values are not exact because some components affect the measured value). In
the overheat situation NTC resistance reduces and machine stops the inverter at the
500Ω point. Note that NTC has descending nominal curve: When temperature rises
resistance lowers.
Z001 card has auxiliary power supply that delivers auxiliary voltages to Z001 card.
There are two secondary voltages: +16VDC for the IGBT gate driver circuits and
+24VDC for the cooling fan and charging relay.
DC-link with three 470μF electrolytic capacitors. Machine current is measured 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.
Spark protection against HF ignition sparks
3.4.2. A001 Control card
MMA dynamics function. Adjustment is made in panel setup.
A001 card has auxiliary power supply; it rectifies the auxiliary transformers secondary
voltage 20VAC to 28VDC. Switching circuit regulates it to +24VDC, and produces un-
regulated +8VDC, from which a +5VDC regulated supply is generated.
PWM circuit for controlling the inverter. Secondary current is measured in the shunt
and feedback is used to make correct adjustments. PWM circuit adjusts also open
circuit voltage and its level can be selected from panel software (+95VDC or 30VDC
VRD).
Secondary voltage measuring. Value is delivered to P001 card.
Connection to P001 card.
Gas valve control circuit. P001 microprocessor gives control signal to A001 card.
Control to DC-link soft start charging relay and over voltage watch.
PFC control circuit. Control signal comes from the microprocessor on the P001 card.
Under voltage watch. It shuts down the inverter and information is delivered to micro-
processor on the P001 card.

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Main transformer PTC and IGBT NTC monitoring circuits. It shuts down the inverter
and information is delivered to microprocessor on the P001 card.
Remote controller and TIG torch control connections. P001 card reads the signals.
3.4.3. A002 spark card
Generates voltage to spark transformer and switches it on and off. Voltage is gener-
ated from the main transformer secondary.
Trimmer R14 can be adjusted to change the voltage between 7,8-14,7kV. A002 card
(both original and spare part card) is factory adjusted 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:
oControls panel LEDs and 7-segment display.
oReads membrane switches and pulse potentiometer.
oReads remote controller and TIG torch control signals (via A001).
oControls cooling fan, gas valve, spark ignition and PFC operations.
oReads over and under voltage watch circuit and over temperature circuit stages.
oControls serial bus and saves calibrations data.
Service connector for programming devices like Datamaster 2. Panel processor can
be re-programmed via this connector.
Panel card holds most of the input and output devises to the user, like LEDs, 7-
segment display, and pulse potentiometer.
Connection to membrane panel.

Service manual MinarcTig Evo 200
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3.4.5. Setup parameters
To enter the setup you have to press back and forward arrows for three seconds:
Parameter
Explanation
A.
1
TIG slopes to minimum current
0*
TIG current at arc stop is 15 % of welding current
b.
1
no load voltage 30 V (VRD function)
0*
no load voltage 95 V
C.
1
by 2T the downslope is cut off by short (<0,4 s) action 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 default
o.
Postgas time maximum
15-99 s
Range
30 s*
Factory default
S.
MMA Dynamics adjustment
-3…5
Range
0*
Factory default
* (asterix) presents the factory default setting
Press 3 seconds for entering setup

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3.4.6. Error codes
Error 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

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4. SERVICE INSTRUCTIONS
4.1. Programming
MinarcTig Evo 200 has a microprocessor on the P001 card. It can be reprogrammed using Datamaster 2
(DM2 later in this document) service device. Panel card has 10-pin connector X10 where DM2 flat cable
can be connected.
Both normal MinarcTig and MLP versions use the same software. First software must be uploaded to the
DM2 using Datamaster 2 PC software, which is provided on a CD included with the DM2. Once the soft-
ware is installed on the PC, it can then be transferred to the DM2 via a USB cable. Now the DM2 is ready
to be used for MinarcTig update.
Open the MinarcTig case and connect the 10-pin connector to 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
4.2.1. Z001 Main circuit card
Power stage is divided in to two parts: rectifier/PFC module and IGBT module. They can be tested sepa-
rately by using simply digital multimeter.
4.2.1.1. Input rectifier and PFC circuit
Main supply voltage must not be connected during the rectifier/PFC module diode measuring.
In many case of primary side failures input rectifier or the PFC circuit diodes may get defective. Rectifier
and PFC diodes can be measured one at a time. PFC has one diode in series with IGBT and one dis-
charge diode.

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Check the diodes using the multimeter 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

Service manual MinarcTig Evo 200
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Diode
Positive test lead
Negative test lead
Result
Diode 1 forward bias
L1
Rectifier output
0,2-0,7VDC
Diode 3 reverse bias
L1
GND
No value
Diode 1 reverse bias
Rectifier output
L1
No value
Diode 3 forward bias
GND
L1
0,2-0,7VDC
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 input
No value
Discharge diode forward bias
GND
PFC input
0,3-0,7VDC
DC-link
positive
PFC input
GND

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4.2.1.2. IGBT
Main supply voltage must not be connected during the IGBT module diode measuring.
IGBT module can be tested by multimeter if using the diode tester function. Module holds four diodes and
in many cases they may be defective if IGBT is damaged. They can be measured separately only if main
transformer primary is disconnected.
IGBT
Positive test lead
Negative test lead
Result
IGBT 1 diode + upper separate
diode; forward bias condition
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 transformer primary is disconnected, IGBT 1 emitter and IGBT 2 collector connection points can be
used separately to measure diodes one by one. In this case the table must checked twice: first using the
IGBT 1 emitter point only and then the IGBT 2 collector point.
GND
IGBT1 emitter
IGBT2
collector
1
2
DC –link positive