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Service Manual Service Manual: Ver. 1.1 Ver. 1.1
Service Manual Service Manual: Ver. 1.1 Ver. 1.1
Ver. 1.1
150
150 VRD
151
Contents
Technical data………………………….……………... 3
data………………………….……………...
Operation principle……………………………………. 4
principle…………………………………….
Main circuit…………………………………….……... 4 - 6
circuit…………………………………….……...
Troubleshooting diagram………………………...…… 7
Block diagram………………………………….…….. 9
diagram………………………………….……..
Measurings...……………………...….. 10, 11
Structure………………………………………………..24, 25
IGBT-transistor testing..............………………………. 26
…………….. 27
Notes............…………………………………………..
Notes............……………………………
Technical data
3
Operation principle
VDC
~ + 320 V 105
5
,
0
.
V1 x
a
M
t
1/3
13µs
V2
Main circuit
R9
X11/12
6 6
1 3 V
V 1 ,
C 5
X1 0 V
2 ,
4
V V
1 X13
3
R
1 L2 L1
2 3
V V 1
, 0
7 0
4 V T
2 C
3 5 ,
R 1 5 9 V11 3
C C C C
,
+t +t 2
X3 C
X12
R30 R23 0 2
1 V
C ,
1 2
V T
0
1
V
,
9
V
,
8
V
K1
X5
R9
X11/12
6 5
1 1 V
V 1
C ,
4
V
,
3
V
X1
X13
X2 3
L1 C
L2 , 2
2
C V 1
, 0
6 0
V T
4
2 6
R 1 9 V10
C C
X3 X12
1
1
X4 0 V
,
1 1
C 5 2
C V T
,
4
X5 C
9
V
,
8
V
,
7
V
C21
R34
V28, V29
L001
X7 X003
1 0 X6
2 2
R R
U
7
1 3
5 0 R35 R 7
2 0 2
T V 3
V , U 3
6 R
2
V24 V
0
2
C
6
2
V X8
X11/11 X9 X004
V19
R11 V30
V28
V22
X11/14 X10
3 6
2 1
V C X21
X11/15
9 4 4 7 9 7 6
2 2 1 1 1 2 3
R R C C C R R
V18 5
2 2
2 R
V X22
C18
X5
5
Main circuit
C21
R34
V28, V29
L001
X7 X003
1 0 X6
2 2
R R
U
7
1 3
5 0 R35 R 7
2 0 2
T V 3
V , U 3
6 R
2
V24 V
0
2
C
6
2
V X8
X11/11 X9 X004
V19
R11 V30
V28
V22
X11/14 X10
3 6
2 1
V C X21
X11/15
9 4 4 7 9 7 6
2 2 1 1 1 2 3
R R C C C R R
V18 5
2 2
2 R
V X22
C18
X5
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.
Troubleshooting diagram
Welding current can´t be adjusted Faulty power adjustment Check the potentiometer condition
by potentiometer R001. potentiometer R001. (R001 = 10 k Ω)
Fault y control card A001. Change control card A001.
7
Main circuit diagrams
Minarc 151
8
Block diagram
A001 Z001
Z002
Relaycard
Minarc 151
9
Operational tests / measurings
C F
B
E
10
Measuring points on main circuit card Z001 (Minarc 150)
D E
A
B
11
Measuring point A. Main transformer T001 primary voltage
16
Measuring point on the flat cable
X1/1 GND
X1/2 Current info from primary
X1/3 GND
X1/4 Gate control, upper IGBTs
G X1/5 Gate control, lower IGBTs
X1/6 GND
X1/7 Supply voltage watch
H X1/8 Temperature watch (PTC:t)
X1/9 GND
I X1/10 Auxiliary voltage (+20…30 V)
X1/11 Signal lamp H2 control / VRD
X1/12 Auxiliary voltage from DC-link
J X1/13 GND
X1/14 Auxiliary voltage +20 V
X1/15 OCV control (~ +85 V)
X1/16 GND
17
Measuring point G. Gate control, upper IGBTs
20
Main circuit card Z001 connectors (Minarc 150)
X9
X8 X13
X7
X11
X10 X12
X6
X1
X3 X5
Main transformer
X10
s
r
o
t
i
c S
a e
p c
a o
c n
g d
n a
i r
y
h
t
o r
e
o c X11
m t
i
S f
i
e
r
EMI
Primary rectifier
LZ101 X5
22
Control card A001 layout
N1
Voltage regulator
(+ 20 V)
X1
N2
PWM-circuit
S1
MMA/TIG
R26
Max. current N3
adjustment Comparator
R35
Min. current
adjustment R49
H2 Current adjustment
ON / VRD ON
H1 N4
Overheat Comparator
protection
23
Structure
A001
Z001
3 mm
24
Structure
25
IGBT-transistor testing
1
/ 2
6 1
/ /
2 E
2
2 C 1/ 3
B E
C
B1/4
T I
R G
O C B
F O 1 T
F N -
T T
R E
O T S
N O T
R
L E
2 R
When testing secondary diodes the other coil end of the main
transformer (T001) must be disconnected. Main transformer
cable connector´s may break if bent!
The soldering must be done carefully, because they are stressed with
high current, approximately 30 A/ leg!
26
Notes
27