Service manual

MinarcTig 180MLP
Version 1.0

MinarcTig
180MLP

1
Table of contents

Technical data......................................................................................3
Main circuit diagram........................................................................... 4
Block diagram..................................................................................... 5
Main circuit card Z001
Operating diagram............................................................... 6
Connectors........................................................................... 7
Measurings...........................................................................8
Control card A001
Operating diagram............................................................... 9
Connectors........................................................................... 10
Spark generator card A002
Connectors / operating diagram..........................................11
Panel card P001
Connectors / operating diagram..........................................12
Operating panel................................................................................... 13
Setup.................................................................................................... 14
Setup functions.................................................................................... 15-17
Error codes...........................................................................................18
Structure.............................................................................................. 19
Power semiconductors testing and replacing...................................... 20
Programming....................................................................................... 21
Troubleshooting...................................................................................22

2
Technical data
Mains voltage 1 ~230 V ±15%, 50 / 60 Hz
Rated power TIG Max. 6,7 kVA (180 A / 17,2 V)
MMA Max. 7,0 kVA (140 A / 25,6 V)
Load capacity TIG 35 % ED 180 A / 17,2 V
100 % ED 120 A / 14,8 V
MMA 35 % ED 140 A / 25,6 V
100 % ED 100 A / 24 V
Supply current, I1max TIG 29 A (180 A/17,2 V)
MMA 31 A (140 A/25,6 V)
Supply current, I1eff TIG 18 A (120 A/14,8 V)
MMA 22 A (100 A/24,0 V)
Connection cable / fuse 3 x 2,5 mm² - 3 m Euro Schuko
Fuse 16 A delayed
Load capacity TIG 35 % ED 180 A/17,2 V
100 % ED 120 A/14,8 V
MMA 35 % ED 140 A/25,6 V
100 % ED 100 A/24 V
Welding range TIG 5 A/10,2 V-180 A/17,2 V
MMA 10 A/20,4 V-140 A/25,6 V
Open circuit voltage 95 V
Idle Power TIG -
MMA 25 W
Power ratio at max. current
TIG / MMA 0,62 / 0,63
Efficiency at max. currentTIG / MMA 0,75 / 0,81
Spark voltage 7-13 kV
MMA welding electrodes MMA Ø1,5-3,25 mm
External dimensions(L x W x (400 x 180 x 340) mm
H)
Weight 7,8 kg (8,4 kg with supply cable)
Degree of protection IP 23 C
Operating temperature range - 20 °C…+ 40 °C
Recommended generator > 7 kVA
3
 Main circuit diagram

PTC, 140 °C Main transformer, T001 Choke, L002

Main switch, S1
PTC, 120 °C
Main circuit card
Aux. transformer, T002
Shunt resistor, R001

Spark transformer, T003

Spark generator card, A002

Control card

Panel card, P001 Solenoid valve, Y001 Fan, M001

4
Block diagram
Control card A001
Aux. Voltage development
Undervoltage monitoring
Over voltage monitoring
Temperature monitoring
Solenoid valve control
Fan control
Power supply control
Panel card P001
Adjustment potentiometer
Parameters selection
Overheat protection signal light
Main switch signal light
Main circuit card Z001
Net over voltage protection
DC-link charging
EMI-filter
Primary rectifier
Energy reserve
”Dual-forward”-inverter
Main transformer
Secondary rectifying
Spark generator card A002
” Spark voltage generator
(=voltage multiplier)
Spark voltage adjustment
5
Main circuit card Z001
Secondary rectifier
DC-link charging,
resistors and relay

Connector to A001
Main transformer,
T001 EMI-filter
Current transformer,
T1

IGBTs, gate
resistors, return Primary rectifier
current diodes
Smoothing capasitors

Operating diagram

- Net over voltage

protection
- DC-link charging
- EMI-filter
Z001 - Primary rectifier
- Energy reserve
- Dual-forward-inverter
- Main transformer
- Secondary rectifier

6
Connectors
X16 X5 X1 X3
X9
A
X10

C X2

X12

B X11

X13

X14

X15

X4

Z001 connectors Measuring point A. X1, X3

X1 Power supply voltage 230 Vac Measuring point B. X2/6, X2/12
X2 Connector A001 Measuring point C Primary rectifier
X3 Power supply voltage 230 Vac
X4 Shunt resistor, (-)
X5 Machine body, equipment earth
X9 Aux. transformer T002 supply voltage ~230 Vac
X10 Aux. transformer T002 supply voltage ~230 Vac
X11 Supply voltage to spark generator card A002
X12 Supply voltage to spark generator card A002
X13 Secondary choke L002, (+)
X14 PTC, main transformer
X15 PTC, main transformer
X16 Machine body, equipment earth
7
Measurings

Measuring point A. Measuring point B.

Supply voltage, main circuit card Z001 Gate control pulse (X2/6, X2/12), no load

Measuring point C.
DC-link charging (primary rectifier)

8
Control card A001
X1 X2 H1
X3

H2

X5

X8

X6
X9

X14 X13

Operating diagram
- Aux. Voltage development
- PWM-control
- Shunt amplifier
- MMA dynamic control
- Solenoid valve control
- Fan control
- Under voltage watch
- Overvoltage watch
- Overheat watch
- Remote/foot control interface
- TIG –torch interface
- Panel interface
- Filtering of control lines 9
Connectors

A001 / X1 A001 / X5
X1/1 I2 measure X5/1 GND
X1/2 U2 measure X5/2 -
X1/3 D1 data X5/3 24 V
X1/4 D1 data X5/4 Pedal start
X1/5 D1 data X5/5 Remote pot
X1/6 Torch potentiometer X5/6 -
X1/7 Remote potentiometer X5/7 +5V
X1/8 Current control
X1/9 D2 data A001 / X6
X1/10 D2 data X6/1 GND
X1/11 D2 data X6/2 SW 1
X1/12 Dynamics X6/3 SW 2
X1/13 Powersource type X6/4 Start
X1/14 Pedal start X6/5 Potentiometer
X1/15 +5V X6/6 -
X1/16 GND X6/7 +5V

A001 / X2 A001 / X8
X2/1 GND X8/1 21 Vac
X2/2 Relay + 24 V X8/2 GND
X2/3 -
X2/4 PTC
X2/5 - A001 / X9
X2/6 Gate control X9/1 I1 measure
X2/7 Overvoltage, opto X9/2 I1 measure
X2/8 Relay on/off
X2/9 U2 measure
X2/10 PTC A001 / X13
X2/11 - X13/1 24 V
X2/12 Gate control X13/2 GND

A001 / X3 A001 / X14

X3/1 PTC X14/1 Spark on / off
X3/2 PTC X14/2 Solenoid valve (+)
X14/3 -
H1 Aux. voltage + 5 V (LED) X14/4 Spark on / off
H2 Aux. voltage + 24 V (LED) X14/5 Solenod valve (-)
X14/6 - 10
Spark generator card A002
Connectors

R9
A002 connectors
X3 X2 X1 Main transformer secondary
X2 Spark on / off
X3 Spark transformer primary
R9 Spark voltage adjustment
X1

Operating diagram

- Spark voltage generator

(=voltage multiplier)
- Spark voltage adjustment

11
Panel card P001
Connectors

P001 Connectors
X1 Connector A001
X2 X10 X2 Membrane panel connection
X3
X10 Program-/service channel

X1

Operating diagram

- Micro controller (Renesas M30262)

- Adjustment potentiometer
- Parameters selection
- Overheat protection signal light
- Main switch signal light

12
Operating panel

Standby
indicator Overheating indicator

Minilog Pulse cycle

Upslope Downslope

Pregas Postgas

Selection arrow Pulse on/off

keys
Control knobb
Process
selection TIG / Panel / remote
selector
MMA
HF ignition ( LED on )
2T / 4T function and
minilog Contact ignition ( LED off )

13
Setup

3
2

1
4

• You can enter the Setup mode by pressing both arrow

keys ( 1 ) for at least five seconds.
• The display will show the name of the parameter ( 2 ) and
numerical value ( 3 ).
• Select the parameter to be adjusted with the arrow buttons
( 1 ), and change value with the control knob ( 4 ).

14
 Setup functions

Name on Parameter Factory Description

display value range setting

A 0 or 1 0 End current level selection. 1=5A, 0=15%

B 0 or 1 0 Open-circuit voltage selection. 1=30V (VRD), 0=95V

C 0 or 1 0 Forced stop during downslope with a brief pressing of the switch. 1=On, 0=Off

d 0,1,2 or 3 1 Alternative switch logic. 0=4T LOG, 1=Minilog,( 2=4T-LOG+Minilog, 3= Minilog+ search arc )

E 5 … 40% 20% Start current level as % of the welding current.

F 0 or 1 0 Restore factory settings. 1=Restore, 0=No restore

h 0.0 … 2.0s 0s Minimum setting of pre-gas time.

J 0.0 … 10.0s 1.0s Minimum setting of post-gas time.

L 5.0 … 20.0s 10.0s Maximum setting of pre-gas time.

o 15 … 99s 30s Maximum setting of post-gas time.

S -3 … 5 0 Arc dynamics (Arc Force)

t -9 … 0 0 Electrode ignition pulse. -9=No pulse, 0=Max pulse

( Available from program version 0A7 )

15
Setup functions
A = End current level selection
With this function you can set the welding current level when the arc will be extinguished.
0 = 15% of the welding current that is used.
1 = minimum current, which is 5 amperes in this power source.
B = Open-circuit selection
With this function you can change the open-circuit voltage.
0 = 95 volts
1 = 30 volts
C = Forced stop during downslope with a brief pressing on the switch
When downslope time is adjusted, the welding current drops normally to the
end current level and the arc is extinguished. This function allows to stop the arc during
the downslope with a quick press from the switch. Works only with 2T.
0 = Off
1 = On
d = Alternative switch logic
With this function it is possible to choose between four different switch logics.
0 = 4T-LOG
1 = Minilog
2 = 4T-LOG + Minilog
3 = Minilog + Search arc
E = Start current level selection (% of the welding current)
With this function you can set the current level when the arc ignites.
The value is a percentage of the welding current. The factory setting is 20%.
If the welding current is set to 100A, the start current level is 20A.
The adjustment range is 5–40%.
F = Restore factory settings
With this function you can reset the parameters to the factory settings.
0 = Do not restore factory settings
1 = Restore factory settings
16
Setup functions
h = Minimum setting for pre-gas time
With this function you can set the pre-gas minimum time to the desired
value in the range 0 – 2 seconds.The factory setting is 0 seconds.
J = Minumum setting for post-gas time
With this function you can set the post-gas minimum time to the desired
value in the range 0 – 10 seconds.The factory setting is 1 second
L = Maximum setting for pre-gas time
With this function you can set the pre-gas maximum time to the desired
value in the range 5 – 20 seconds. The factory setting is 10 seconds.
o = Maximum setting for post-gas time
With this function you can set the post-gas maximum time to the desired
value in the range 15 – 99 seconds. The factory setting is 30 seconds.
S = Arc dynamics ( Arc Force )
When welding with MMA the power source automatically adjusts the dynamics.
With this function it is possible to adjust the dynamics manually.
Adjustment range is -3 - +5
-3 = ( softer arc )
+5 = ( harder arc )
t = Electrode ignition pulse
When welding with MMA the power source automatically adjusts the ignition pulse.
With this function it is possible to adjust the ignition pulse manually.
Adjustment range is -9 – 0
-9 = No ignition pulse
0 = Maximum ignition pulse

17
Error codes
E2: Power source undervoltage
The machine has stopped because it has detected a mains undervoltage that disturbs welding.
Check the quality of the supply network.

E3: Power source overvoltage

The machine has stopped the welding because it has detected momentary voltage spikes or
continuous overvoltage dangerous to the machine in the electric network.
Check the quality of the supply network

E4: Power source overheating

The power source has overheated. The cause may be one of the following.
The power source has been used for a long time at maximum power
The circulation of cooling air to the power source is blocked
The cooling system has experienced a failure

Notice !
Remove any obstacle to air circulation, and wait until the power source fan has cooled down
the machine.

18
Structure
Membrane panel Panel card, P001 Control card, A001

Main switch, S001

Solenoid valve,
Y001

Fan, M002

Spark generator card, Aux. transformer, T002

A002

Main circuit card, Z001 Choke, L002

Spark transformer, T003

Main Shunt resistor,

transformer, R001
T001
19
Power semiconductor testing and replacing

A separate discrete-IGBTs can be tested only when disconnected

from the board with IGBT-tester.

When replacing damaged IGBTs, the whole set has to be

replaced, including gate resistors!!

Discrete-IGBT and secondary diodes tightening torque to the heat

sink is 0,6…1,2 Nm.

G C E
C2E1/1

E2/2
B2/6

C1/3

B1/4
IGBT-TESTER
TR 1
OFF

CONTROL
ON

TR 2

20
Programming

1. Start DataMaster II and press Menu.

2. Select Renesas Programming using UART mode.

3. Use the up and down arrows to choose the program you want to download.

4. Press START on the DataMaster II keypad to start the updating process.

5. When DataMaster II display says: Connect Programmable Device, connect

DataMaster II (10-pin flat cable) to welding machine (panel card connector X10) and press CONTINUE.

6. Wait so long time that programming that Datamaster display shows: Programming Ok.

7. When updating is in progress, the DataMaster II display shows the progression of

the process as a percentage value. If the progression stops, reset the DataMaster
II by pressing ON/OFF key for 3 seconds, and start again.

21
Troubleshooting
Problem Possible cause
The power doesn’t start Aux transformer T002
Panels signal light (green) is not ignited
Control card A001
Th net fuses blow when starting Faulty primary circuit semiconductor
machine
Aux. transformer T002
Only program version is showing Membrane panel is broken
nn display Membrane panel flat cabel is broken
The power source doesn’t deliver A faulty primary rectifier V9
full power
A faulty smoothing capasitors
A faulty secondary rectifier
A faulty control card A001
TIG-high frequency spark doesn’t A faulty spark generator card A002
ignite A faulty Spark generator card A002
Remedy
Chech aux. Transformer T002
Secondary voltage between connectors
X8/1-X8/2. (approx. 23 Vac)
If aux. Transformer secondary voltage
Is approx. 23 Vac, then replace control
card A001
Check the primary side semiconductors.
See IGBT-testing on page 23
Check aux. Transformer T002 condition
Change membrane panel
Check membrane panel functionality.
Unconnect membrane connection from
Panel card and check machine
functionality
Check the primary rectifier condition and
solderings
Check smoothing capasitors condition
And solderings
Check the secondary diodes and
solderings
Change control card A001
Check A002/X2-connector supply voltage
Change spark generator card
22