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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
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