Service manual

Ver. 1.1

Contents
General....3 Operating panel..3 Technical data 4 Operating principle4 Main circuit ....5 Main circuit diagram.6 Control card A001 connectors X3 and X5...6 Block diagram.7 Troubleshooting..8 Operational tests / measurings..............9 DC-link charging..10 IGBT gate pulse........11 Main transformer T001 primary voltage......12 Main transformer T001 secondary voltage 1/2....13 Main transformer T001 secondary voltage 2/214 Secondary voltage before choke...15 Auxiliary voltages.....16 Plate thickness adj. set value.................17 Voltage fine tune pot. set value.............18 Wire feed power supply.............8 Wire feed motor max. voltage..................18 Main circuit card Z001 layout...19 Main circuit card connectors and measuring points...20 Control card A001 layout. 21 Control card A002 layout. 21 Structure. 22 Power semiconductors testing and replacing.. 23

General
MinarcMigTM Adaptive 150-power source has adaptive control; the welder uses one knob to select the weled plate thickness and the power source automatically finds the optimal welding parameters. Arc dynamics is optimized according to the adjusted plate thickness, filler wire and shielding gas.
1. The plate thickness is selected 2. The filler wire is detected by the short circuits, and according to this information the arc properties are automatically optimized. Adaptive power increase Voltage

Current Power adjustment by one knob Short circuit 2,0...3,0 ms

Operating panel

Arc length adjustment Plate thickness selection Main switch signal lamp Overheat protection signal lamp

Normal setting

Short arc

Long arc

Technical data
Supply voltage, 1~ 50/60 Hz Loadability 35% ED 60% ED 100% ED Supply cable / fuses Adjustment range Wire feed speed adjustment range OCV Efficiency Power factor Filler wires 230 V 15% 150 A / 21,5 V (6,9 kVA) 120 A / 20,0 V (5,3 kVA) 100 A / 19,0 V (4,2 kVA) 2,5 mm S - 3,3 m / 16 A 20 A / 13,5 V150 A / 22,0 V 1,011,0 m/min 2231 V 0,8 (150 A / 21,5 V) 0,58 (150 A / 21,5 V) 0,61,0 mm 0,81,0 mm IP 23C 400 mm 180 mm 340 mm 9,4 kg

Fe, Ss Flux core wire Al Length Width Height

Degree of protection Dimensions

Weight (including gun and cables)

Operating principle
MinarcMig Adaptive 150-power sources are dual-Forward-inverters, controlled by PWM principle. Switching components are IGBT transistors. Operating frequency of the power source is approximately 80 kHz. Below is a principle picture of a dual-forward-inverter:
approx. + 320 V V1 VDC 75 V3 V4 t 13s V2

The power is adjusted by altering the IGBT-transistor (V1 and V2) timings (PWM). When IGBTtransistors are in non-conductive state the current is reduced and passes through diode V4.

X4
X5 X1 X3 X18
R15

U
R20 R17

X17

R14

X2/5

X20
V25 K1 V26

Main circuit

Primary circuit.

Secondary circuit.
C14 R21 C15 R16

+t +t

R19 R18

X2/4

V23
C13

V21

L2

X19
V24 V22
C11 C9

ML2

MA2

ML1 X14
V20

MA1 X2/8
X2/1 X2/2

C12

C10

L1

V19

X9

X16

R13

U
R12 V18 C4

R11

X2/3

C1, C2, C3

R1 V14, V15, V16, V17

V10, V11, V12, V13

V9 R2

V5, V6, V7, V8

V1, V2, V3, V4

X2/9

T1

X2/10
T001

X13

X12

Main circuit diagram

Main switch Wire feed motor Solenoid valve Aux. transformer Gun start switch EMI-choke Main transformer

Fan Operating panel Control card Main circuit card

PTC

Secondary choke

Control card A001 connector X3 X3/1 GND X3/2 GND X3/3 Opto (net voltage watch) X3/4 + 24 V (DC-link charging relay K1) X3/5 DC-link charging relay K1 control X3/6 IGBT gate pulse X3/7 X3/8 Output voltage (U2) X3/9 Current transformer X3/10 Current transformer X3/11 Temperature watch PTC X3/12 X3/13 Temperature watch PTC X3/14 X3/15 X3/16 -

Control card A001 connector X5 X5/1 Voltage adjustment potentiometer R002 (+) X5/2 Voltage adjustment potentiometer R002 (-) X5/3 Voltage adjustment potentiometer R002 glide X5/4 Overheat signal lamp H001 (-) X5/5 Overheat signal lamp H001 (+) X5/6 On-signal lamp H002 (-) X5/7 On-signal lamp H002 (+) X5/8 Plate thickness potentiometer R001 glide X5/9 Plate thickness potentiometer R001 (-) X5/10 Plate thickness potentiometer R001 (+)

Block diagram

Control card A001 Auxiliary voltages development Undervoltage watch Overvoltage watch Temperature watch Wire feed control and power stage Solenoid valve control Power stage control

Main circuit diagram Z001 Overvoltage protection DC-link charging EMI-filter Primary rectifier Energy reserve Dual-forward-inverter Secondary rectifying

16

10 Operating panel A002 Plate thickness adj. potentiometer Voltage fine adjustment potentiometer Overheat signal lamp Main switch signal lamp

Troubleshooting
The machine may be repaired only by an authorized and licensed technician or workshop! First do a visual check to find the possible loose connectors, broken wires or signs of overheating. Also note the condition of the consumable parts of the wire feeder and welding gun, because most problems in MIG/MAG-welding are related to wire feeding.

Troubleshooting diagram
PROBLEM The power doesnt start, panels signal lamp H002 is not lighted POSSIBLE CAUSE Aux. transformer T002 REMEDY Check aux. transformer T002 secondary voltage between connectors X1/7-X1/8 (approx. 23 Vac) If aux. transformer secondary voltage is approx. 23 Vac, then replace control card A001 Check the primary side semiconductors. See the IGBT testing on page 23 Check auxiliary transformer T002 condition Check the condition of the plate thickness potentiometer (R001 = 10 k) Replace control card A001 Check the primary rectifier condition and solderings Check the smoothing capacitors C1C3 and solderings Check the secondary diodes and solderings Replace control card A001 Check control card resistor R39 condition and replace as necessary (R39 = 47 / 1 W)

Control card A001

The net fuses blow in machine start

Faulty primary circuit semiconductor

Auxiliary transformer T002 Welding power doesnt follow the plate thickness potentiometer R001 A faulty plate thickness potentiometer R001 A faulty control card A001 The power source doesnt deliver full power A faulty primary rectifier V9 A faulty smoothing capacitor A faulty secondary rectifier A faulty control card A001 Wire feeding is sticky and the arc is interrupted Control card A001 resistor R39

Operational tests / measurings

D A C E

B F

Measuring point A. DC-link charging Measuring point B. IGBT gate pulse Measuring point C. Main transformer T001 primary voltage Measuring point D. Main transformer T001 other secondary coil voltage Measuring point E. Main transformer T001 Voltage of both secondary coils Measuring point F. Secondary voltage before choke

Measuring point A. DC-link charging

X17 X3
V1, V2, V3, V4 R11 V26

R17

R12

R2

X12
V10, V11, V12, V13

L2 V25 R20

L1 C1, C2, C3

C13

C10

V19

R13

C9

C4

V9

X1 X18

+t
R19

+t
C11 R18

A
V14, V15, V16, V17

T001

X13
T1

X2/10 X2/9
V5, V6, V7, V8

C12

X2/5 X5

K1

X2/4

Primary Secondary
X2/1 X2/2 X2/3
V18

DC-link smoothing capacitors C1, C2 and C3 are charged through PTC-resistors R18 and R19 (25 ), which reduces thr switching transient conducting to the net. DC-link charging takes approximately 0,7 s.

R1

10

Measuring point B. IGBT gate pulse With setting: plate thickness adjustment = maximum, voltage fine tune = middle point With load: LVR 600 = resistance 200 as load (100 A / 15 V)
11

Measuring point C. Main transformer T001 primary voltage With setting: plate thickness adjustment = maximum, voltage fine tune = middle point With load: LVR 600 = resistance 200 as load (100 A / 15 V)
12

Measuring point D. Main transformer T001 other secondary coil voltage With setting: plate thickness adjustment = maximum, voltage fine tune = middle point With load: LVR 600 = resistance 200 as load (100 A / 15 V)
13

Measuring point E. Main transformer T001 voltage of both secondary coils With setting: plate thickness adjustment = maximum, voltage fine tune = middle point With load: LVR 600 = resistance 200 as load (100 A / 15 V)
14

Measuring point F. Secondary voltage before choke With setting: plate thickness adjustment = maximum, voltage fine tune = middle point With load: LVR 600 = resistance 200 as load (100 A / 15 V)
15

Auxiliary voltages

Measuring point G. Auxiliary transformer T002 secondary voltage

+ 30 V
N1

+ 24 V 217 O A
R114 C5 R12

I X2/2
V13 V16 C15 C6

T002

M002

X5/7

X1/8
V15 V14

H002

Auxiliary voltages are formed from auxiliary transformer T002 secondary voltage: + 30 V for fan M002, DC-link charging relay K1 and solenoid valve Y001, regulated + 24 V for power stage PWM controller D1 and gate buffer and +15 V for other electronics.

X5/6

X2/1

V23

R11

C10

R93

X1/7

+ 15 V

16

Plate thickness and voltage fine tune set values

I H

Measuring point H. Plate thickness set to min - max, (A001 X5/8-X3/1)

Measuring point I. Voltage adjustment short arc - long arc, (A001 X5/3-X3/1)

17

Wire feed power supply and wire feed motor voltage

K J

Measuring point J. Wire feed power supply (A001 X1/5-X3/1)

Measuring point K. Wire feed motors average voltage max. (A001 X1/5-X1/6)

18

Main circuit card Z001 layout

Secondary rectifier DC-link charging resistors and relay Main transformer T001 Pulse transformer T2 EMI-filter Current transformer T1 IGBTs, gate resistors and return-diodes Primary rectifier

Smoothing capacitors

19

Main circuit card Z001 connectors and measuring points

X3 X17 X5 X18 X20 X21 X14 X22 X2 B ML2 A X1

X12 X9 F ML1 C E MA2 MA1 D X4 X13 X19 X16

Measuringpoint A. DC-link charging Measuringpoint B. IGBT gate pulse Measuringpoint C. Main transformer T001 primary voltage Measuringpoint D. Main transformer T001voltage of the other secondary coil Measuringpoint E. Main transformer T001 voltage of both secondary coils Measuringpoint F. Secondary voltage before choke

20

Control card A001 layout

X4 X5

X1

X2 R10 Wf-max. X3

Control card A002 layout

R001 Plate thickness

R002 Voltage H001

X1

H002

21

Structure

Main switch S001 Choke LZ101 Solenoid valve Y001

Control card A002 Wire feed motor M001

Fan M002 Main circuit card Z001

Secondary choke L001

Control card A001

Aux. transformer T002

22

Power semiconductor testing and replacing

Discrete-IGBTs can be tested by IGBT-tester.
G C E

When replacing damaged IGBT-transistors, they must allways be changed as a set including the gate resistors!!
C2E1/1

The tightening torque of the discrete-IGBTs and secondary diodes to the heatsink is 0,61,2 Nm.
IGBT-TESTER TR 1 OFF ON CONTROL

B2/6

E2/2

C1/3

B1/4

TR 2

Notes

23