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Summary of Contents for Kemppi Minarc Evo 150
- Page 1 SERVICE MANUAL Minarc Evo 150/180 Kemppi Oy...
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Page 2: Table Of Contents
4.4. Semiconductor installation ........................26 4.4.1. Rectifier/PFC module and IGBT ...................... 26 4.4.2. Secondary rectifier ........................... 27 4.5. Final testing ............................. 27 4.5.1. Load bank test ..........................28 4.5.2. Test welding ............................. 28 5. NOTES ................................29 APPENDIX ................................29 Kemppi Oy... -
Page 3: Read This First
Service manual Minarc Evo 150 and 180 Version 1.3 30.9.2015 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. -
Page 4: General
30.9.2015 2. GENERAL Minarc Evo 150 and 180 are new generation small MMA machines. It is not based on any existing machine. It is totally new design electrically and mechanically. Machine has a power factor correction in the primary side to meet the latest European regulations. -
Page 5: Technical Information
Service manual Minarc Evo 150 and 180 Version 1.3 30.9.2015 3. TECHNICAL INFORMATION 3.1. Technical data Minarc Evo 150 Kemppi Oy... - Page 6 Service manual Minarc Evo 150 and 180 Version 1.3 30.9.2015 Minarc Evo 180 Kemppi Oy...
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Page 7: Wiring Diagram
Service manual Minarc Evo 150 and 180 Version 1.3 30.9.2015 3.2. Wiring diagram Latest version with better quality is available at Kemppi Channel. Kemppi Oy... -
Page 8: Construction
Service manual Minarc Evo 150 and 180 Version 1.3 30.9.2015 3.3. Construction Front Left side Right side Back Left side, side plate Left side plate with removed cooling fan The cooling fan is installed so that the air flows from the left side plate to Z001 card. Air comes out through the front and the back plate grills. -
Page 9: Inner Structure
Service manual Minarc Evo 150 and 180 Version 1.3 30.9.2015 3.3.1. Inner structure 1. Main switch 2. Primary heat sink 3. T001 main transformer 4. Secondary heat sink 5. Secondary choke 6. Remote control socket 7. A001 control card 8. Z001 main circuit card... -
Page 10: Z001 Main Circuit Card Structure
Service manual Minarc Evo 150 and 180 Version 1.3 30.9.2015 3.3.2. Z001 main circuit card structure Primary rectifier and PFC module IGBT module DC-link capacitors Main transformer Secondary diodes, zero side + stress reduction resistor Negative output connector Positive output connection... -
Page 11: A001 Control Card Structure
Service manual Minarc Evo 150 and 180 Version 1.3 30.9.2015 3.3.3. A001 control card structure X2 service connector (not field programmable, serial bus connection is in the primary side) MMA/TIG selection Remote ON/OFF Microcontroller Analogic potentiometer 7-segment display X1 connector to main circuit card (flat cable) -
Page 12: Description Of Operation
Service manual Minarc Evo 150 and 180 Version 1.3 30.9.2015 3.4. Description of operation Minarc Evo 150/180 can be divided to two parts: Z001 main circuit card and A001 control/panel card Z001 main circuit card Input rectifier and PFC circuit... -
Page 13: A001 Control Card
VDR led is off in A001 card. 3.4.2. A001 Control card Minarc Evo 150 and 180 are using same control card but software is different so also spare part codes are different. Cards are not programmable in field. ... -
Page 14: Service Instructions
4. SERVICE INSTRUCTIONS 4.1. Programming Minarc Evo 150/180 has a microprocessor on the A001 card. This can only be reprogrammed in Kemppi production because great care must be taken, because the connection is in the primary potential and without galvanic isolation. - Page 15 Service manual Minarc Evo 150 and 180 Version 1.3 30.9.2015 Moving from parameter to parameter can be done by combining the Remote ON/OFF and TIG/MMA buttons in the following sequence. Moving to next parameter: 2. Press to go to the next parameter 1.
- Page 16 Service manual Minarc Evo 150 and 180 Version 1.3 30.9.2015 Parameter values can be changed by using the buttons Remote ON/OFF and TIG/MMA separately. Increasing the parameter value: Press to increase the parameter value Parameter 3: Display current offset min. (10A)
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Page 17: Calibration Parameters
Once machine is switched off, restart the machine to get the parameter values reset. Note! This parameter is only for resetting the calibration data; this is not the factory settings recall as in the other Kemppi machines. After resetting the values, procedure must be carried out to ensure the machine working properly. -
Page 18: Measurements And Tests
Service manual Minarc Evo 150 and 180 Version 1.3 30.9.2015 The following example uses a clamp meter. See the previous two chapters to study button configurations (Pictures 2 and 3) and parameter info (Picture4). 1. Switch off the machine. If a resistive load is available, this is the best option, connect the resistive load via welding cables between the machine output Dix connectors. -
Page 19: Input Rectifier And Pfc Circuit
Service manual Minarc Evo 150 and 180 Version 1.3 30.9.2015 4.3.1.1. Input rectifier and PFC circuit Mains supply voltage must be connected during the rectifier/PFC module diode measuring. In many cases of primary side failures input rectifier or the PFC circuit diodes may be broken. Rectifier diodes can be measured one by one, but PFC circuit diodes only in two groups, because they are internally connected parallel and in series. - Page 20 Service manual Minarc Evo 150 and 180 Version 1.3 30.9.2015 Rectifier output Diode Positive test lead Negative test lead Result Diode 1 forward bias Rectifier output 0,2-0,7VDC Diode 3 reverse bias No value Diode 1 reverse bias Rectifier output No value...
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Page 21: Igbt
Service manual Minarc Evo 150 and 180 Version 1.3 30.9.2015 PFC input DC-link Diode group Positive test lead Negative test lead Result Series diodes forward bias PFC input DC-link positive 0,2-0,5VDC IGBT diodes reverse bias PFC input No value Series diodes reverse bias... - Page 22 Service manual Minarc Evo 150 and 180 Version 1.3 30.9.2015 IGBT 1 emitter and IGBT 2 collector are connected via main transformer; it is not possible to measure all the four diodes separately without disconnecting the transformer primary. Main transformer...
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Page 23: Secondary Rectifier
Service manual Minarc Evo 150 and 180 Version 1.3 30.9.2015 Minarc Evo 180 card: DC-link IGBT 2 IGBT 1 collector emitter IGBT 1 emitter IGBT Positive test lead Negative test lead Result IGBT 1 diode + upper separate IGBT1 emitter/IGBT 2... -
Page 24: Voltages
Service manual Minarc Evo 150 and 180 Version 1.3 30.9.2015 4.3.1.4. Voltages The Z001 main circuit card has the DC-link voltage after the input rectifier and several auxiliary voltages made by the auxiliary PSU. Floating point voltage and remote control reference voltage need their own ground points to get right values. -
Page 25: Overheat Protection
Service manual Minarc Evo 150 and 180 Version 1.3 30.9.2015 +12VDC, Test point on the right side of R22 Reference ground, N3 right side, third leg from top Primary GND, +390VDC, DC-link, 4.3.1.5. Overheat protection Main transformer PTC is soldered to the Z001 main circuit card: ... -
Page 26: A001 Control Card
Service manual Minarc Evo 150 and 180 Version 1.3 30.9.2015 PTC common point Main transformer PTC resistor Both primary modules NTCs are integrated inside the module: Measure the resistance, it should be between 60-15kΩ in a cool machine (in environment temperature 0-40°C) - Page 27 Service manual Minarc Evo 150 and 180 Version 1.3 30.9.2015 Control card voltages have common ground, on the primary side. +16VDC and +24VDC PSU are located on the Z001 card. +5VDC is made on the A001 card. Note! Voltages are in the primary side. Even touching the ground level may affect electric shock because there is up to 120VDC between the primary ground and protective earth.
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Page 28: Cooling Fan
4.3.4. Low voltage tests Low voltage test cannot be done to Minarc Evo 150 machine. 4.3.5. Safety tests Safety tests are made normally, but PE conductivity test cannot be tested, because there are no outer parts connected to PE. -
Page 29: Secondary Rectifier
Service manual Minarc Evo 150 and 180 Version 1.3 30.9.2015 Hexagonal screws Support cap Support cap screw 4.4.2. Secondary rectifier The heat sink transfer compound should spread in an even layer onto the heat sink. Then the card should be immediately mounted onto the heat sink, this minimizes the possibility of any contamination (dirt etc.) getting between the components. -
Page 30: Load Bank Test
Output voltage should be 25,6V. Example: Minarc Evo 150 MMA mode load bank test, welding current 140A and output voltage 25,6V Turn the machines main switch OFF Connect machine to the load bank and check that there is no load added. -
Page 31: Notes
Service manual Minarc Evo 150 and 180 Version 1.3 30.9.2015 5. NOTES Kemppi Oy...
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Dziękuje za pomoc w naprawie tego modelu, przyczyną awarii w moim przypadku to przerwa na wyprowadzeniu cewki PFC, zapewne z powodu zbyt mało stabilnego jej zamocowania do PCB.