Kemppi MinarcTig Evo 200 Service Manual
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Kemppi MinarcTig Evo 200 Service Manual

Tig and mma machine
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SERVICE MANUAL
MinarcTig Evo 200
Kemppi Oy

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Summary of Contents for Kemppi MinarcTig Evo 200

  • Page 1 SERVICE MANUAL MinarcTig Evo 200 Kemppi Oy...

  • Page 2: Table Of Contents

    4.2.4. Low voltage tests ..........................22 4.2.5. Safety tests ............................22 4.3. Semiconductor installation ........................22 4.3.1. Rectifier/PFC module and IGBT ...................... 22 4.3.2. Secondary rectifier ........................... 23 4.4. Final testing ............................. 23 5. NOTES ................................24 APPENDIX ................................24 Kemppi Oy...

  • Page 3: Read This First

    Service manual MinarcTig Evo 200 Version 1.1.5. 29.9.2015 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

    The MinarcTig Evo machines are for DC TIG and MMA-welding. MinarcTig Evo 200 can be connected to the mains supply of 230VAC 1~. PFC makes possible to weld with the full power (TIG 200A) even when modern circuit breakers are used.

  • Page 5: Technical Information

    Service manual MinarcTig Evo 200 Version 1.1.5. 29.9.2015 3. TECHNICAL INFORMATION 3.1. Technical data MinarcTig Evo 200 Connection voltage 1~50/60 Hz 230V ± 15% Rated power 25 % ED TIG 200 A/4.5 kVA 35 % ED MMA 170 A/ 5.8 kVA 19.8 A...

  • Page 6: Wiring Diagrams

    Service manual MinarcTig Evo 200 Version 1.1.5. 29.9.2015 3.2. Wiring diagrams Kemppi Oy...

  • Page 7: Construction

    Service manual MinarcTig Evo 200 Version 1.1.5. 29.9.2015 3.3. Construction Front Left side Right side Back Left side plate is installed with T20 (4 pieces) torx screws and side plate has to be removed before opening case. Case itself is kept in place with T15 (12 pieces) torx screws.

  • Page 8: Inner Structure

    Service manual MinarcTig Evo 200 Version 1.1.5. 29.9.2015 3.3.1. Inner structure 1. Main switch 2. Primary heat sink 3. T001 main transformer 4. Secondary heat sink 5. Spark transformer 6. Remote control socket 7. P001 panel card 8. A001 control card 9.

  • Page 9: Z001 Main Circuit Card Structure

    Service manual MinarcTig Evo 200 Version 1.1.5. 29.9.2015 3.3.2. Z001 main circuit card structure 1. Primary rectifier and PFC module 2. IGBT module 3. DC-link capacitors 4. Main transformer 5. Secondary diodes, zero side 6. Work return connection 7. Positive output connection 8.

  • Page 10: A001 Control Card Structure

    Service manual MinarcTig Evo 200 Version 1.1.5. 29.9.2015 3.3.3. A001 control card structure 1. X2 connector to A002 control card 2. Shunt connection to the A001 card (X8 brown, X7 black) 3. X5 Remote control connector 4. X1 connector to P001 panel card 5.

  • Page 11: A002 Spark Card Structure

    Service manual MinarcTig Evo 200 Version 1.1.5. 29.9.2015 3.3.4. A002 spark card structure 1. X3 Spark transformer connector (output) 2. X1 Main transformer secondary connector (input) 3. X2 Control card connector (Spark ON/OFF) 3.3.5. P001 panel card structure 1. X10 Service connector for Datamaster 2 2.

  • Page 12: Description Of Operation

    Service manual MinarcTig Evo 200 Version 1.1.5. 29.9.2015 3.4. Description of operation MinarcTig Evo has the following parts and components:  Main circuit card Z001  Control card A001  Spark card A002  Panel card P001  Main switch S001 ...

  • Page 13: A001 Control Card

    Service manual MinarcTig Evo 200 Version 1.1.5. 29.9.2015 diode and PFC choke) keeps the primary currents and voltage in the same phase. This rises the power factor up to 0,98. PFC is boost type and raises the DC-link volt- age up to 390VDC.

  • Page 14: A002 Spark Card

    Service manual MinarcTig Evo 200 Version 1.1.5. 29.9.2015  Main transformer PTC and IGBT NTC monitoring circuits. It shuts down the inverter and information is delivered to microprocessor on the P001 card.  Remote controller and TIG torch control connections. P001 card reads the signals.

  • Page 15: Setup Parameters

    Service manual MinarcTig Evo 200 Version 1.1.5. 29.9.2015 3.4.5. Setup parameters To enter the setup you have to press back and forward arrows for three seconds: Press 3 seconds for entering setup Parameter Explanation TIG slopes to minimum current TIG current at arc stop is 15 % of welding current...

  • Page 16: Error Codes

    Service manual MinarcTig Evo 200 Version 1.1.5. 29.9.2015 3.4.6. Error codes Error code Explanation Supply voltage is too low Supply voltage is too high Main transformer overheated Secondary voltage too high (safety limit 113 V) E.13 Panel card and control card versions do not match. One of them is AU version and another one non-AU version.

  • Page 17: Service Instructions

    4. SERVICE INSTRUCTIONS 4.1. Programming MinarcTig Evo 200 has a microprocessor on the P001 card. It can be reprogrammed using Datamaster 2 (DM2 later in this document) service device. Panel card has 10-pin connector X10 where DM2 flat cable can be connected.
  • Page 18 Service manual MinarcTig Evo 200 Version 1.1.5. 29.9.2015 Series diode Discharge diode Check the diodes using the multimeter diode function to measure their threshold voltage. Diodes must be measured both forward bias and reverse bias condition to make sure they are fine. See following pictures and tables to make sure all the measurements are done.
  • Page 19 Service manual MinarcTig Evo 200 Version 1.1.5. 29.9.2015 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 Diode 3 forward bias...

  • Page 20: Igbt

    Service manual MinarcTig Evo 200 Version 1.1.5. 29.9.2015 4.2.1.2. IGBT Main supply voltage must be connected during the IGBT module diode measuring. IGBT module can be tested by multimeter if using the diode tester function. Module holds four diodes and in many cases they may be defective if IGBT is damaged.

  • Page 21: Secondary Rectifier

    Service manual MinarcTig Evo 200 Version 1.1.5. 29.9.2015 4.2.1.3. Secondary rectifier Main supply voltage must be connected during the secondary rectifier diode measuring. Use a digital multimeter to test the secondary diodes. Diodes are in groups, so it is not possible to meas- ure them one by one unless they removed from the board and measured separately.

  • Page 22: Overheat Protection

    Service manual MinarcTig Evo 200 Version 1.1.5. 29.9.2015 Primary GND, +390VDC, DC-link, 4.2.1.5. Overheat protection Main transformer PTC is soldered to the Z001 main circuit card:  Measure the resistance: It should be less than 100Ω  In over temperature situation PTC goes to high-resistance mode (>10kΩ) ...
  • Page 23 Service manual MinarcTig Evo 200 Version 1.1.5. 29.9.2015 IGBT module NTC is integrated inside the module:  Measure the resistance, it should be between 14-2,8kΩ in a cool machine (in environ- ment temperature 0-40°C)  While temperature rises, resistance lowers and at 500Ω point the inverter stops and gives overheat alert.

  • Page 24: A001 Control Card

    4.3.1. Rectifier/PFC module and IGBT MinarcTig Evo 200 has a soldering input rectifier/PFC and IGBT modules and it is not possible to change them separately. Only reliable way to replace the module(s) is to change the whole Z001 main circuit card.

  • Page 25: Secondary Rectifier

    Service manual MinarcTig Evo 200 Version 1.1.5. 29.9.2015 Heat sink paste should be spread on to the modules in an even layer by using clean fingers. Then the card should be immediately mounted onto the heat sink, this minimizes the possibility of any contamina- tion (dirt etc.) getting between the components.

  • Page 26: Notes

    Service manual MinarcTig Evo 200 Version 1.1.5. 29.9.2015 5. NOTES Kemppi Oy...

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