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Service manualMinarcTig 180MLP

Version 1.0

180MLPMinarcTig

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Table of contents

Technical data......................................................................................3Main circuit diagram........................................................................... 4Block diagram..................................................................................... 5Main circuit card Z001

Operating diagram............................................................... 6Connectors........................................................................... 7Measurings...........................................................................8

Control card A001Operating diagram............................................................... 9Connectors........................................................................... 10

Spark generator card A002Connectors / operating diagram..........................................11

Panel card P001Connectors / operating diagram..........................................12

Operating panel................................................................................... 13Setup.................................................................................................... 14Setup functions.................................................................................... 15-17Error codes...........................................................................................18Structure.............................................................................................. 19Power semiconductors testing and replacing...................................... 20Programming....................................................................................... 21Troubleshooting...................................................................................22

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Technical data

Mains voltage 1 ~230 V ±15%, 50 / 60 HzTIGMMA

Max. 6,7 kVA (180 A / 17,2 V) Max. 7,0 kVA (140 A / 25,6 V)180 A / 17,2 V120 A / 14,8 V140 A / 25,6 V100 A / 24 V

Supply current, I1max TIG MMA

29 A (180 A/17,2 V)31 A (140 A/25,6 V)

Fuse 16 A delayedTIG 35 % ED 180 A/17,2 V

100 % ED 120 A/14,8 VMMA 35 % ED 140 A/25,6 V

100 % ED 100 A/24 VWelding range TIG

MMA5 A/10,2 V-180 A/17,2 V10 A/20,4 V-140 A/25,6 V

Idle Power TIGMMA

-25 W

MMA welding electrodes MMA Ø1,5-3,25 mm

Load capacity

Supply current, I1eff TIGMMA

18 A (120 A/14,8 V)22 A (100 A/24,0 V)

Connection cable / fuse 3 x 2,5 mm² - 3 m Euro Schuko

Open circuit voltage 95 V

Power ratio at max. current TIG / MMA 0,62 / 0,63Efficiency at max. current TIG / MMA 0,75 / 0,81Spark voltage 7-13 kV

External dimensions(L x W x H)

(400 x 180 x 340) mm

Weight 7,8 kg (8,4 kg with supply cable)Degree of protection IP 23 COperating temperature range - 20 °C…+ 40 °CRecommended generator > 7 kVA

TIG 35 % ED 100 % ED

MMA 35 % ED100 % ED

Rated power

Load capacity

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Main circuit diagram

Solenoid valve, Y001 Fan, M001

Main switch, S1

Spark transformer, T003

Choke, L002Main transformer, T001

Aux. transformer, T002

Shunt resistor, R001

PTC, 140 °C

PTC, 120 °C

Control card

Main circuit card

Spark generator card, A002

Panel card, P001

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Block diagram

Control card A001Aux. Voltage developmentUndervoltage monitoringOver voltage monitoringTemperature monitoringSolenoid valve control

Fan controlPower supply control

Main circuit card Z001Net over voltage protection

DC-link chargingEMI-filter

Primary rectifierEnergy reserve

”Dual-forward”-inverterMain transformer

Secondary rectifying

Panel card P001Adjustment potentiometer

Parameters selectionOverheat protection signal light

Main switch signal light

Spark generator card A002” Spark voltage generator

(=voltage multiplier)Spark voltage adjustment

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Main circuit card Z001

Secondary rectifier

Current transformer, T1

DC-link charging, resistors and relay

EMI-filter

IGBTs, gate resistors, return current diodes

Main transformer, T001

Smoothing capasitors

Primary rectifier

Connector to A001

Operating diagram

- Net over voltageprotection

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

Z001

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ConnectorsX16 X5 X1

X12

X2

X3

X11

X15

X14

X13

X9

X10

X4

C

B

A

X1 Power supply voltage 230 VacX2 Connector A001X3 Power supply voltage 230 VacX4 Shunt resistor, (-)X5 Machine body, equipment earthX9 Aux. transformer T002 supply voltage ~230 Vac

X10 Aux. transformer T002 supply voltage ~230 VacX11 Supply voltage to spark generator card A002

Z001 connectors

X12 Supply voltage to spark generator card A002X13 Secondary choke L002, (+)X14 PTC, main transformerX15 PTC, main transformerX16 Machine body, equipment earth

Measuring point A. X1, X3Measuring point B. X2/6, X2/12Measuring point C Primary rectifier

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Measurings

Measuring point A.Supply voltage, main circuit card Z001

Measuring point B.Gate control pulse (X2/6, X2/12), no load

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

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Control card A001

X13X14

X9

X8

X3X2X1

X5

X6

H2

H1

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

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Connectors

X1/1 I2 measureX1/2 U2 measureX1/3 D1 dataX1/4 D1 dataX1/5 D1 dataX1/6 Torch potentiometerX1/7 Remote potentiometerX1/8 Current controlX1/9 D2 data X1/10 D2 data

A001 / X1

X1/11 D2 dataX1/12 DynamicsX1/13 Powersource typeX1/14 Pedal startX1/15 + 5 VX1/16 GND

X2/1 GNDX2/2 Relay + 24 VX2/3 -X2/4 PTCX2/5 -X2/6 Gate controlX2/7 Overvoltage, optoX2/8 Relay on/offX2/9 U2 measureX2/10 PTC

A001 / X2

X2/11 -X2/12 Gate control

X3/1 PTCX3/2 PTC

A001 / X3

X5/1 GNDX5/2 -X5/3 24 VX5/4 Pedal startX5/5 Remote potX5/6 -X5/7 + 5 V

A001 / X5

X6/1 GNDX6/2 SW 1X6/3 SW 2X6/4 StartX6/5 PotentiometerX6/6 -X6/7 + 5 V

A001 / X6

X8/1 21 VacX8/2 GND

A001 / X8

X9/1 I1 measureX9/2 I1 measure

A001 / X9

X13/1 24 VX13/2 GND

A001 / X13

X14/1 Spark on / offX14/2 Solenoid valve (+)X14/3 -X14/4 Spark on / offX14/5 Solenod valve (-)X14/6 -

A001 / X14

H1 Aux. voltage + 5 V (LED)H2 Aux. voltage + 24 V (LED)

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Spark generator card A002

Connectors

R9

X2

X1

X3 X1 Main transformer secondaryX2 Spark on / offX3 Spark transformer primaryR9 Spark voltage adjustment

A002 connectors

Operating diagram

- Spark voltage generator(=voltage multiplier)

- Spark voltage adjustment

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Panel card P001

Connectors

X3X2 X10

X1

X1 Connector A001X2 Membrane panel connection

X10 Program-/service channel

P001 Connectors

Operating diagram

- Micro controller (Renesas M30262)- Adjustment potentiometer- Parameters selection- Overheat protection signal light- Main switch signal light

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Operating panel

2T / 4T function and minilog

Process selection TIG / MMA

Selection arrow keys

Pregas

Upslope

Standbyindicator Overheating indicator

Downslope

Postgas

Panel / remote selector

Control knobb

Pulse on/off

HF ignition ( LED on )Contact ignition ( LED off )

Minilog Pulse cycle

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Setup

1

2

4

3

• 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 ).

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Setup functions

Electrode ignition pulse. -9=No pulse, 0=Max pulse0-9 … 0t

Arc dynamics (Arc Force)0-3 … 5S

Maximum setting of post-gas time.30s15 … 99so

Maximum setting of pre-gas time.10.0s5.0 … 20.0sL

J

h

F

E

d

C

B

A

Name ondisplay

1.0s

0s

0

20%

1

0

0

0

Factorysetting

Forced stop during downslope with a brief pressing of the switch. 1=On, 0=Off0 or 1

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

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

Restore factory settings. 1=Restore, 0=No restore0 or 1

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

Minimum setting of post-gas time.

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

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

Description

0.0 … 10.0s

Parametervalue range

0 or 1

0 or 1

( Available from program version 0A7 )

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Setup functionsA = 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 volts1 = 30 volts

C = Forced stop during downslope with a brief pressing on the switchWhen 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 duringthe downslope with a quick press from the switch. Works only with 2T.0 = Off1 = On

d = Alternative switch logicWith this function it is possible to choose between four different switch logics. 0 = 4T-LOG1 = Minilog2 = 4T-LOG + Minilog3 = 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 settingsWith this function you can reset the parameters to the factory settings.

0 = Do not restore factory settings1 = Restore factory settings

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Setup functionsh = Minimum setting for pre-gas time

With this function you can set the pre-gas minimum time to the desiredvalue in the range 0 – 2 seconds.The factory setting is 0 seconds.

J = Minumum setting for post-gas timeWith this function you can set the post-gas minimum time to the desiredvalue in the range 0 – 10 seconds.The factory setting is 1 second

L = Maximum setting for pre-gas timeWith this function you can set the pre-gas maximum time to the desiredvalue in the range 5 – 20 seconds. The factory setting is 10 seconds.

o = Maximum setting for post-gas timeWith this function you can set the post-gas maximum time to the desiredvalue 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

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Error codesE2: Power source undervoltageThe machine has stopped because it has detected a mains undervoltage that disturbs welding. Check the quality of the supply network.

E3: Power source overvoltageThe machine has stopped the welding because it has detected momentary voltage spikes orcontinuous overvoltage dangerous to the machine in the electric network. Check the quality of the supply network

E4: Power source overheatingThe power source has overheated. The cause may be one of the following.The power source has been used for a long time at maximum powerThe circulation of cooling air to the power source is blockedThe cooling system has experienced a failure

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

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Structure

Main switch, S001

Solenoid valve,Y001

Fan, M002

Control card, A001

Spark generator card, A002

Panel card, P001

Aux. transformer, T002

Membrane panel

Main circuit card, Z001 Choke, L002

Shunt resistor, R001

Spark transformer, T003

Main transformer, T001

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Power semiconductor testing and replacing

A separate discrete-IGBTs can be tested only when disconnectedfrom the board with IGBT-tester.

When replacing damaged IGBTs, the whole set has to bereplaced, including gate resistors!!

Discrete-IGBT and secondary diodes tightening torque to the heatsink is 0,6…1,2 Nm.

G C E

IGBT-T

ESTER

TR 1

TR 2

CO

NTRO

L

OFF O

N

B2/6

C2E1/1

E2/2

C1/3

B1/4

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

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Troubleshooting

Problem Possible cause RemedyThe power doesn’t startPanels signal light (green) is not ignited

Aux transformer T002 Chech aux. Transformer T002Secondary voltage between connectorsX8/1-X8/2. (approx. 23 Vac)

Control card A001 If aux. Transformer secondary voltageIs approx. 23 Vac, then replace control card A001

Th net fuses blow when startingmachine

Faulty primary circuit semiconductor Check the primary side semiconductors.See IGBT-testing on page 23

Aux. transformer T002 Check aux. Transformer T002 condition

Only program version is showingnn display

Membrane panel is brokenCheck membrane panel functionality.Unconnect membrane connection fromPanel card and check machinefunctionality

The power source doesn’t deliverfull power

A faulty primary rectifier V9 Check the primary rectifier condition andsolderings

A faulty smoothing capasitors Check smoothing capasitors conditionAnd solderings

A faulty secondary rectifier Check the secondary diodes and solderings

A faulty control card A001 Change control card A001

TIG-high frequency spark doesn’tignite

A faulty spark generator card A002 Check A002/X2-connector supply voltage

Change spark generator card

Membrane panel flat cabel is broken

A faulty Spark generator card A002

Change membrane panel