Service manual

1
Contents

Electrostatic Discharge............................................................................................. 3
Tools and testing equipments................................................................................... 4
General, operating panel……………………………………………............................ 5
Block diagram…….................................................................................................... 6
Main circuit diagram................................................................................................. 7
Main circuit…………………………………………………………............................... 8
Operating principle................................................................................................... 9
Main circuit card Z001 / layout………....................................................................... 10
Main circuit card Z001 connectors / measuring points............................................. 11
Main circuit card Z001 measurings…………………….............................................. 12-15
Control card A001 layout / connectors……………....................................................16
Control card A001 connectors.................................................................................. 17
Control card A002 layout / connectors...................................................................... 18
Construction………………………………………………………………………………. 19
Power semiconductors testing and replacing........................................................... 20
Troubleshooting………............................................................................................. 21
Technical data…....................................................................................................... 22

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Electrostatic Discharge

Electrostatic discharge (ESD) is phenomenon that occurs almost everywhere and often.
At its most powerful, it is known as thunder and lightning electrical charges as high as
one billion volts can be discharged between clouds or between clouds and the ground
below. This type of electrical discharge cannot occur at normal ground level, of course.

Movement and friction generate static discharges of a few thousand volts in certain
conditions. For example, stroking a cat can generate thousands of volts.

Electronic appliances welding machines included are now designed and manufactured in
ways that take into account the ESD problem. It is only apparent when an appliance is
taken apart for servicing. At that time the ground terminal is often disconnected and
sensitive electronic components can be prone to electrostatic discharge. The best way to
protect against ESD when handling electronic cards or microchips is an earth
connection. You frequently hear of people who wonder why a new, unused electronic
card works at first and then stops working afterwards. The reason may well be that some
of its components are damaged by ESD. Memory circuits are especially sensitive. It may
be that a memory circuit damaged by ESD breaks down only weeks later. It looks like a
software problem but in fact it is a tiny defect in the memory circuit itself.

A simple, effective enough way to protect against ESD is to wear an earth bracelet when
handling electronic circuits or cards. The bracelet is earthed to the frame of the
appliance being serviced. An equally important shielding device is an earth pad on the
workbench. Also wearing clothing manufactured from natural fiber (cotton) decreases
electrical charging.

All Kemppi factory parts susceptible to ESD (e.g. control cards) are delivered in
packaging or pouches that protect and earth the components. Packets and pouches carry
yellow ESD labels. Parts susceptible to ESD must be kept in their original packages only
removed just before installation.

Article taken from Kemppi PRONEWS

3
Tools and testing equipments

While repairing Kemppi machines there is no need to have any

special hand tools. Most of the work can be done with normal
workshop tools and testing can be done by digital multimeter and
Kemppi Multipower or a standard workshop power source.

Hand tools and accessories:

Metric combination wrenches 8-19mm, 28mm
Screwdrivers: flat 0,5 x 3mm and torx T10-T25
Needle-nose pliers
Side cutters
Cable ties

Testing equipments:
Digital multimeter True RMS (800VDC, 600VAC for safe operation)
Regular power source (with 50VDC output) or Kemppi Multipower
(~28 VAC, 50VDC)

Useful extra tools:

Digital oscilloscope 10MHz or greater

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General

MinarcMigTM Adaptive power sources has adaptive control; The user

selects the welded plate thickness with one knob (1) and the power source
automatically adjusts the optimum welding parameters. Arc dynamics is
optimized according to plate thickness setting, filler wire and shielding gas.

The machine is suitable for a range of different purpose and the possibility
to use a long supply cable (3 x 2,5 mm², 50 meters).

Suitable for generator use (min 4,2 kVA recommended 8,0 kVA for max.
power).

Operating Panel:

1. Welding power control, plate thickness

2. Arc length trimmer
3. Standby indicator light
4. Overheating indicator light

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Block diagram

Control card A001 Main circuit card Z001

• Aux. voltages development • Overvoltage protection

• Undervoltage monitoring 16 • DC-link charging
• Overvoltage monitoring • EMI-filter
• Temperature monitoring • Primary rectifier
• Wire feed control and power stage • Energy reserve
• Solenoid valve control • ”Dual-forward”-inverter
• Power supply control • Secondary rectifying

10
Operation panel A002

• Plate thickness adj. potentiometer

• Voltage fine tune potentiometer
• Overheat protection indicator lamp
• Standy indicator lamp

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Main circuit diagram

Main components: Main components:

A001, control card T001, main transformer
A002, operating panel T002, auxliary transformer
L001, secondary choke X002, gun switch
LZ101, EMI choke X003, dix (+)
M001, cooling fan X004, dix (-)
M002, Wire feeder motor Y001, solenoid valve
RT101, ptc (main transformer) Z001, main circuit card
S001, main switch

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Main circuit

Primary circuit
X17
X3

V1, V2, V3, V4

R11
V26

R2
R17

R12
X12

V10, V11, V12, V13

L2 L1
V25

T001
R20

C1, C2, C3
R13
V19
C10
C13

C4
C9

V9
+t +t
X1 X13

V14, V15, V16, V17

C11

R19 R18

T1
X18 X2/10
X2/9

R1
C12

V5, V6, V7, V8

X2/5 K1
X2/4
X5
Primary
V18

Secondary
X2/1 X2/3
X2/2

Secondary circuit
X4

V23 V24
R16

X2/8
X14
C15

X9
R21
U
R15

R14
C14

V21 V22 V20 X16

X20

ML2

MA2
X19

ML1

MA1

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Operating principle

MinarcMig Adaptive 170-power source is ”dual-Forward”-inverter,

controlled by PWM principle. Switching components are IGBT transistors.
Operating frequency of the power source is approximately 80 kHz. Below is
a principle picture of a ”dual-forward”-inverter:

n. + 320 V VDC

V1 V3 75

V4

t
n. 13µs
V2

Power is adjusted by changing IGBT-transistors V1 and V2 switching ON

time (PWM). When IGBT transistors are in non-conductive state, output
current is smaller and is rectified by null diode V4.

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Main circuit card Z001 layout

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 Main circuit card Z001 connectors / measuring
points

X3

X5 X17

X20 X18

X21 A X1

X14

X2 X22

X12
B

ML2

X9

F
C ML1

MA2
E

MA1
D
X4

X16
X13 X19

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Main circuit card Z001 measurings

D
A
E
C

Measuring point A: DC-link charging

Measuring point B: IGBT gate pulse (X2/6, X2/12)
Measuring point C: Main transformer T001 primary voltage
Measuring point D: Main transformer T001 other secondary coil voltage
Measuring point E: Main transformer T001 voltage of both secondary coils
Measuring point F: Secondary voltage before choke

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Main circuit card Z001 measurings

Measuring point A: DC-link charging

Measuring point B: IGBT gate pulse (X2/6, X2/12)

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Main circuit card Z001 measurings

Measuring point C: Main transformer T001 primary voltage

Measuring point D: Main transformer T001 other secondary coil voltage

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Main circuit card Z001 measurings

Measuring point E: Main transformer T001 voltage of both secondary coils

Measuring point F: Secondary voltage before choke

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Control card A001 layout / connectors

X5

X1

X2

R10
Wf-max speed adjustment
X3

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Control card A001 connectors

Control card A001 / X1 Control card A001 / X2

X1/1 Start X2/1 Fan (+)
X1/2 Solenoid valve Y001 (-) X2/2 Fan (+)
X1/3 Solenoid valve Y001 (-)
X1/4 M keski
X1/5 Wire feeding motor (+)
X1/6 Wire feeding motor (-) Control card A001 / X5

X1/7 T002 X5/1 Voltage adjustment potentiometer R002 (+)

X1/8 T002 X5/2 Voltage adjustment potentiometer R002 (-)

X1/9 - X5/3 Voltage adjustment potentiometer R002 glide

X1/10 - X5/4 Overheat signal lamp H001 (-)

X1/11 Start X5/5 Overheat signal lamp H001 (+)

X1/12 GND X5/6 On-signal lamp H002 (-)

X5/7 On-signal lamp H002 (+)
X5/8 Plate thickness potentiometer R001 glide
X5/9 Plate thickness potentiometer R001 (-)
Control card A001 / X3 X3/10 Plate thickness potentiometer R001 (+)
X3/1 GND
X3/2 GND
X3/3 Opto (net voltage watch)
X3/4 + 24 V (DC-link charging relay K1)
X3/5 DC-link charging relay K1 control
X3/6 IGBT gate pulse
X3/7 -
X3/8 Output voltage (U2)
X3/9 Current transformer
X3/10 Current transformer
X3/11 Temperature watch PTC
X3/12 -
X3/13 Temperature watch PTC
X3/14 -
X3/15 -
X3/16 -

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Control card A002 layout / connectors
R001

X1

H001

H002

R002

Connectors
H1 (H001) Standby indicator light
H2 (H002) Overheating indicator light
R1 (R001) Plate thickness
R2 (R002) Welding power control
X1 Connection to control card A001

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Construction

Main switch Control card

S001 A002

Choke
LZ101
Wire feeder
Solenoid motor M001
valve S001

Fan
M002
Secondary
Main circuit choke L001
card Z001

Control card
A001

Aux. transfor-
mer T002

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Power semiconductor testing and replacing

A separate discrete-IGBTs can be tested only when disconnected

from the 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 C E
C2E1/1

E2/2
B2/6

C1/3

B1/4
IGBT-TESTER
TR 1
OFF

CONTROL
ON

TR 2

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Troubleshooting

First do a visual check to find the possible loose connectors, broken wires
or signs of overheating.
Also note the condition of the consumable parts of the wire feeder and
welding gun because most of problems in MIG/MAG-welding are related to
wire feeding.

Problem Possible cause Action

The power doesn’t start, panel signal Aux transformer T002 Chech aux. transformer T002 secon-
lamp H002 is not ignited dary voltage between connectors
X1/7-X1/8. (approx. 23 Vac)

Control card A001 If aux. transformer secondary voltage Is approx.

23 Vac, then replace control card A001

Th net fuses blow when starting Faulty primary circuit semiconductor Check the primary side
Machine semiconductors. See IGBT-testing!

Aux. transformer T002 Check aux. transformer T002

condition

Welding power doesn’t follow the A faulty plate thickness potentio- Check plate thickness potentiometer
plate thickness potentiometer R001 meter R001 condition: R001 = 10 Kohm

A faulty control card A001 Change control card A001

The power source doesn’t deliver A faulty primary rectifier V9 Check the primary rectifier condition and
full power solderings

A faulty smoothing capasitors Check smoothing capasitors condition

and solderings

A faulty secondary rectifier Check the secondary diodes and

solderings

A faulty control card A001 Change control card A001

Wire feeding is sticky and the arc is Wire liner is stucked Check all mechanical parts
interrupted
Wire feeding motor doesn’t work Check motor supply voltage

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Technical data

Connection voltage 1 ~230 V ±15%, 50 / 60 Hz

Rated power 25% ED 8,0 kVA 170 A
60% ED 5,3 kVA 120 A
100% ED 4,2 kVA 100 A
Connection cable H07RN-F 3G2,5 (3 m)
Fuse (delayed) 16 A
Load capacity 40° C 25% ED 170 A/22,5 V
60% ED 120 A/20,0 V
100% ED 100 A/19,0 V
Adjustment range 20-170 A/15-22,5 V

Wire feed adjustment range 1-12 m/min

Open circuit voltage 22-33 V
Power factor at max. current 0,6 (170A/22,5V)
Efficiency at max. current 80 % (150A/21,5V)
Filler wires Fe solid wire ø 0,6...1,0 mm
Fe cored wire ø 0,8...1,0 mm
Shielding gases CO², Ar+CO² -mixed gases
Wire spool (max. ø) 200 mm

Temperature class H (180°C)/F (155°C)

External dimensions LxWxH 400 x 180 x 340 mm
Weight (incl. gun and cables 3,0 kg) 9,8 kg
Operating temperature range -20°C...+40°C
Storage temperature range -40°C...+60°C
EMC class A
Degree of protection IP23S
Recommended generator size Min 4,2 kVA, 8.0 kVA for max. power

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