Serv rvic icee manu manuaal Mi narc narcT Ti g 180MLP Versi Ve rsion on 1. 1.00
MinarcTig 180MLP
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Table of contents contents Technical data......................................................................................3 Main circuit diagram....................................... .................................... 4 Block diagram..................................................................................... 5 Main circuit card Z001 Operating diagram.................................. diagram............................................................... ............................. 6 Connectors............................. .............................................. Connectors..................................................................... ...... 7 Measurings...........................................................................8 Control card A001 Operating diagram.................................. diagram............................................................... ............................. 9 Connectors..................................................................... Connectors............................. .............................................. ...... 10 Spark generator card A002 Connectors / operating diagram..........................................11 Panel card P001 Connectors / operating diagram..........................................12 Operating panel................................................................................... 13 Setup............................................................................... Setup....................................... ............................................................. ..................... 14 Setup functions............................. functions................................................................... ....................................................... ................. 15-17 Error codes...........................................................................................18 Structure.............................................................................................. 19 Power semiconductors testing and replacing...................................... 20 Programming....................................................................................... Programming............................................... ........................................ 21 Troubleshooting...................................................................................22
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Technical data Mains voltage Rated power
TIG
1 ~230 V 15%, 50 / 60 Hz Max. 6,7 kVA (180 A / 17,2 V)
Load capacity
MMA TIG
35 % ED
Max. 7,0 kVA (140 A / 25,6 V) 180 A / 17,2 V
MMA
100 % ED 35 % ED
120 A / 14,8 V 140 A / 25,6 V
100 % ED
100 A / 24 V 29 A (180 A/17,2 V) 31 A (140 A/25,6 V) 18 A (120 A/14,8 V)
Supply current, I1max Supply current, I1eff
TIG MMA TIG MMA
Connection cable / fuse Fuse Load capacity
Welding range
TIG
22 A (100 A/24,0 V) 3 x 2,5 mm² - 3 m Euro Schuko 16 A delayed 35 % ED 180 A/17,2 V
MMA
100 % ED 120 A/14,8 V 35 % ED 140 A/25,6 V
TIG
100 % ED 100 A/24 V 5 A/10,2 V-180 A/17,2 V
MMA Open circuit voltage Idle Power
TIG MMA TIG / MMA TIG / MMA
Power ratio at max. current Efficiency at max. current Spark voltage MMA welding electrodes MMA External dimensions(L x W x H) Weight Degree of protection Operating temperature range Recommended generator
10 A/20,4 V-140 A/25,6 V 95 V 25 W 0,62 / 0,63 0,75 / 0,81 7-13 kV Ø1,5-3,25 mm (400 x 180 x 340) mm 7,8 kg (8,4 kg with supply cable) IP 23 C - 20 C…+ 40 C > 7 kVA 3
Main circuit diagram
PTC, 140 °C
Main transformer, T001
Choke, L002
Main switch, S1 Main circuit card
Aux. transformer, T002
PTC, 120 °C Shunt resistor, R001
Spark transformer, T003 Spark generator card, A002
Control card
Panel card, P001
Solenoid valve, Y001 Fan, M001
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Block diagram
Control card A001 Aux. Voltage development Undervoltage monitoring Over voltagemonitoring Temperature monitoring Solenoid valve control Fan control Power supply control
Main circuit card Z001 Net over voltage protection DC-link charging EMI-filter Primaryrectifier Energyreserve ”Dual-forward”-inverter Main transformer Secondary rectifying
Panel card P001 Adjustment potentiometer Parameters selection Overheat protection signal light Main switch signal light
Spark generator card A002 ” Spark voltage generator (=voltagemultiplier) Spark voltage adjustment
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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 current diodes
Primaryrectifier
Smoothing capasitors
Operating diagram
Z001
- Net over voltage protection - DC-link charging - EMI-filter - Primary rectifier - Energyreserve - Dual-forward-inverter - Main transformer - Secondary rectifier 6
Connectors X16
X5
X1
X3 X9
A
X10 X2
C
X12 B
X11 X13 X14 X15
X4
X1 X2 X3 X4 X5 X9 X10 X11 X12 X13 X14 X15 X16
Z001 connectors Power supply voltage 230 Vac Connector A001 Power supply voltage 230 Vac Shunt resistor, (-) Machine body, equipment earth Aux. transformer T002 supplyvoltage ~230 Vac Aux. transformer T002 supplyvoltage ~230 Vac Supply voltage to spark generator card A002 Supply voltage to spark generator card A002 Secondary choke L002, (+) PTC, main transformer PTC, main transformer Machine body, equipment earth
Measuring point A. X1, X3 Measuring point B. X2/6, X2/12 Measuring point C Primaryrectifier
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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 (primaryrectifier)
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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 –torchinterface - Panel interface - Filtering of control lines
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Connectors A001 / X5
A001 / X1 X1/1 X1/2 X1/3 X1/4 X1/5 X1/6 X1/7 X1/8 X1/9 X1/10 X1/11 X1/12 X1/13 X1/14 X1/15 X1/16
I2 measure U2 measure D1 data D1 data D1 data Torchpotentiometer Remote potentiometer Current control D2 data D2 data D2 data Dynamics Powersourcetype Pedal start +5V GND
X5/1 X5/2 X5/3 X5/4 X5/5 X5/6 X5/7
GND 24 V Pedal start Remote pot +5V
A001 / X6 X6/1 X6/2 X6/3 X6/4 X6/5 X6/6 X6/7
GND SW 1 SW 2 Start Potentiometer +5V
A001 / X2 X2/1 X2/2 X2/3 X2/4 X2/5 X2/6 X2/7 X2/8 X2/9 X2/10 X2/11 X2/12
GND Relay + 24 V PTC Gate control Overvoltage, opto Relayon/off U2 measure PTC Gate control
A001 / X8 X8/1 X8/2
A001 / X9 X9/1 X9/2
H1 H2
PTC PTC Aux. voltage + 5 V (LED) Aux. voltage + 24 V (LED)
I1 measure I1 measure
A001 / X13 X13/1 X13/2
24 V GND
X14/1 X14/2 X14/3 X14/4 X14/5 X14/6
A001 / X14 Spark on / off Solenoid valve (+) Spark on / off Solenod valve (-) -
A001 / X3 X3/1 X3/2
21 Vac GND
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Spark generator card A002 Connectors R9 X3
X2
X1 X2 X3 R9
A002 c onnecto rs Main transformer secondary Spark on / off Spark transformer primary Spark voltage adjustment
X1
Operating diagram - Spark voltage generator (=voltagemultiplier) - Spark voltageadjustment
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Panel card P001 Connectors
X2
X3
X10
X1 X2 X10
P001 Connectors Connector A001 Membrane panel connection Program-/service channel
X1
Operating diagram
- Microcontroller (RenesasM30262) - Adjustment potentiometer - Parameters selection - Overheat protection signal light - Main switchsignal light
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Operating panel
Standby indicator
Overheating indicator
Minilog
Pulse cycle
Upslope
Downslope
Pregas
Postgas
Selection arrow keys
Pulse on/off Control knobb
Process selection TIG / MMA 2T / 4T functio n and minilog
Panel / remote selector HF igni tion ( LED on ) Contact ign ition ( LED off )
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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 ).
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Setup functions
Name on display
Parameter value range
Factory setting
Description
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 )
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Setup functions A = End current lev el sel ectio n 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 functionallows to stop the arcduring the downslope with a quick pressfromthe switch. Works only with 2T. 0 = Off 1 = On
d = Alternative switch logic With this functionit is possible to choosebetween four different switchlogics. 0 = 4T-LOG 1 = Minilog 2 = 4T-LOG + Minilog 3 = Minilog + Searcharc
E = Start current level selection (% of the welding cur rent) 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 factorysettings 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 s etting for p re-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 sourceautomatically adjusts the dynamics. With this functionit 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 ignitionpulse. With this functionit is possibleto adjust the ignition pulse manually. Adjustment range is -9 – 0 -9 = No ignitionpulse 0 = Maximumignition pulse
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Error codes E2: Power source undervoltage The machine has stopped because it has detected a mains undervoltagethat disturbs welding. Check the quality of the supply network.
E3: Power source overvoltage The machine has stoppedthe welding because it has detected momentary voltagespikes or continuous overvoltage dangerous to the machine in the electric network. Check the quality of the supply network
E4: Power source overheating The power sourcehas overheated. The causemay be one of the following. The power source has beenusedfor a long time at maximumpower The circulation of cooling air to the power sourceis blocked The cooling systemhas experienced a failure
Notice ! Remove any obstacle to air circulation, and wait until the power source fan has cooled down the machine.
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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 transformer, T001
Shunt resistor, R001
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Power semiconductor testing and replacing A separatediscrete-IGBTs can be tested only when disconnected fromthe 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
6 / 2 B
C
1 / 1 E 2 C
E
2 / 2 E
C 1/ 3 B1/4
O F F O N
C O N T R O L
T R 1 T R 2
I G B T T E S T E R
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Programming
1. Start DataMaster II and press Menu . 2. Select RenesasProgramming using UART mode. 3. Usethe up and down arrows to choose the programyouwant 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 cardconnector 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 percentagevalue. If the progression stops, reset the DataMaster II by pressing ON/OFF keyfor 3 seconds, and start again.
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Troubleshooting Problem
Possible cause
The power doesn’t start Aux transformer T002 Panels signal light (green) is not ignited
Th net fusesblowwhen starting machine
Only programversion is showing nndisplay
The power source doesn’t deliver full power
TIG-highfrequency spark doesn’t ignite
Remedy Chech aux. Transformer T002 Secondary voltage between connectors X8/1-X8/2. (approx. 23 Vac)
Control card A001
If aux. Transformer secondaryvoltage Is approx. 23 Vac, then replace control card A001
Faulty primarycircuit semiconductor
Check the primaryside semiconductors. See IGBT-testing onpage 23
Aux. transformer T002
Check aux. Transformer T002 condition
Membranepanel is broken
Change membranepanel
Membranepanel flat cabel is broken
Checkmembrane panel functionality. Unconnect membraneconnection from Panel card and check machine functionality
A faulty primaryrectifier V9
Check the primaryrectifier condition and solderings
A faulty smoothing capasitors
Check smoothing capasitorscondition And solderings
A faulty secondaryrectifier
Check the secondarydiodes and solderings
A faulty control card A001
Change control card A001
A faulty sparkgenerator card A002
Check A002/X2-connector supplyvoltage
A faulty Sparkgenerator card A002
Changespark generator card
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