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0740 801 022 Valid for serial no. 718-xxx-xxxx to 950-xxx-xxxx100628
Aristot
MechTig 3000i
Service manual
S0740 801 022/E100628/P56
- 2 -TOCe
Rights reserved to alter specifications without notice.
READ THIS FIRST 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INTRODUCTION 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TECHNICAL DATA 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WIRING DIAGRAM 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Component description 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MechTig 3000i 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DESCRIPTION OF OPERATION 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2AP1 Interference suppressor board and main rectifier 12. . . . . . . . . . . . . . . . . . . . . . . . . . . .
10AP1 Tig board 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10AP1:1 Power supply 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10AP1:2 Communication with the control board 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10AP1:3 Gas valve 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10AP1:4 HF generator 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10AP1:5 TIG torch switch 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10AP1 Component positions 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15 The power module 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15AP1 Power board 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15AP1:1 Internal power supply 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15AP1:2 Temperature monitoring 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15AP1:3 Overvoltage and undervoltage protection 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15AP1:4 Charging circuit 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15AP1:5 Gate driver stages and switching circuits 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15AP1:6 Fan control 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15AP1 Component positions 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15AP2 Secondary board 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15AP2:1 Diode modules 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15AP2:2 Temperature monitoring 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15AP2 Component positions 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20AP1 Control board 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20AP1:1 Power supply 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20AP1:2 Fan control 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20AP1:3 The CAN bus 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting sequence 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Communication interruptions 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Terminating resistors 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20AP1:4 Temperature monitoring 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20AP1:5 Overvoltage and undervoltage protection 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20AP1:6 Relay driver stages 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20AP1:7 Gate pulses 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20AP1:8 Current sensor 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20AP1:9 Arc voltage feedback 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Open-circuit voltage control 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20AP1 Circuit board versions 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20AP1 Component positions, version 1 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20AP1 Component positions, version 2 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOTE CONTROLS 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EVENT LOG 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Unit numbers 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Code description, power source 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SERVICE INSTRUCTIONS 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
What is ESD? 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service aid 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special tools 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking power board 15AP1 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Rights reserved to alter specifications without notice.
Checking secondary board 15AP2 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Soft starting 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting components on the heat sink 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thermal paste 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rectifier bridge 2BR1 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power board 15AP1 with semicunductor modules 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diode modules 15D1, 15D2 and secondary board 15AP2 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Calibrating the current sensor signal 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Calibration of the arc voltage feedback 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTRUCTIONS 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SAFETY 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connections and control devices 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fan control 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overheating protection 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Welding power source 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tube welding tool 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FAULT-TRACING 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPARE PARTS 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
NOTES 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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READ THIS FIRST
Maintenance and repair work should be performed by an experienced person, and
electrical work only by a trained electrician. Use only recommended replacement parts.
This service manual is intended for use by technicians with electrical/electronic training for
help in connection with fault-tracing and repair.
Use the wiring diagram as a form of index for the description of operation. The circuit
boards are divided into numbered blocks, which are described individually in more detail in
the description of operation. Component names in the wiring diagram are listed in the
component description.
Use the spare parts list as a guide to where the components are located in the equipment.
The spare parts list is published as a separate document, see page 55.
This manual contains details of all design changes that have been made up to and
including June 2010.
The manual is valid for
MechTig 3000i with serial no. 718-xxx-xxxx and 950-xxx-xxxx.
The MechTig 3000i is designed and tested in accordance with international and
European standards IEC/EN 60974.
On completion of service or repair work, it is the responsibility of the person(s)
performing the work to ensure that the product still complies with the requirements of
the above standard.
WARNING!
Many parts of the power source are at mains voltage.
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INTRODUCTION
MechTig 3000i is a welding power source intended for mechanized welding. It is intended
for use with control unit MechControl 2 or MechControl 4. All settings are made from the
control unit.
Schematic diagram of the power source
Design structure of the power source
The power source is transistor-controlled, operating on the inverter principle. It consists of a
number of function modules, as shown in the schematic diagram above. Each module has a
module number, which is always included as the first part of the name/identification of
components in the module.
The modules have the following main functions:
2 Mains module
Mains interference suppressor, mains switch, auxiliary transformer, contactor.
10 TIG module
Comprises all TIG functions.
15 Power module
This module is a dual forward inverter, operating at a switching frequency of 2 x 40 kHz.
IGBT transistors are used as the switching elements. All power semiconductors are built
into modules in order to ensure a robust design.
20 Processor board module (controller module)
This is the controller board, 20AP1, with a microprocessor, that monitors and controls the
voltage and current.
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TECHNICAL DATA
MechTig 3000i
Mains voltage 400 V, 10%, 3∼ 50/60 Hz
Primary current I
max
14.1 A
No-load power demand when in the
energy-saving mode, 6.5 min. after welding
30 W
Permissible load
35% duty cycle
60% duty cycle
100% duty cycle
300 A / 22 V
240 A / 19.6 V
200 A / 18 V
Power factor at maximum current 0.89
Efficiency at maximum current 81.5 %
Open-circuit voltage See page 29
Operating temperature -10 to +40 ° C
Transportation temperature -25 to +55 ° C
Constant sound pressure in no-load < 70 dB (A)
Dimensions lxwxh 652 x 249 x 423 mm
Weight 35 kg
Insulation class transformer H
Enclosure class IP 23
Application class
Duty cycle
The duty cycle refers to the time as a percentage of a ten-minute period that you can weld at a cer
tain load without overloading. The duty cycle is valid for 40° C.
Enclosure class
The IP code indicates the enclosure class, i. e. the degree of protection against penetration by solid
objects or water. Equipment marked IP23 is designed for indoor and outdoor use.
Application class
The symbol indicates that the power source is designed for use in areas with increased
electrical hazard.
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WIRING DIAGRAM
The power source consists of a number of function modules, which are described in the
component descriptions on the following pages. Wire numbers and component names in
the wiring diagrams show to which module each component belongs.
Wires/cables within modules are marked 100 - 6999.
Wires/cables between modules are marked 7000 - 7999.
Components outside modules - e.g. capacitors - are named such as C1 - C99,
connectors XS1 - XS99 (S = socket), XP1 - XP99 (P = plug), XT1 - XT99 (T = terminal).
Circuit boards within each module have names such as 20AP1 - 20AP99.
20 = module association, 1-69
AP = circuit board
1 = individual identification number, 0-99
Transistors within particular modules have identification numbers such as 15Q1 -
15Q99.
15 = module association, 1-69
Q = transistor
1 = individual identification number, 0-99
Component description
Component Description
2 Mains module. Wire numbers 200-299.
2AP1, 2BR1 Interference suppressor board with main rectifier. See diagram on page
12 and the assembly instructions for the rectifier on page 46.
2FU1
Fuse, 0.5 A, slow blow (anti-surge).
2FU2 Fuse, 3.15 A, slow blow (anti-surge).
2FU3 Fuse, 4 A, slow blow (anti-surge).
2FU4 Fuse, 8 A, slow blow (anti-surge).
2L1 - 2L4 Ferrite ring cores.
2QF1 Main On / Off switch.
2TC1 Auxiliary transformer.
3 Primary inductor module. Wire numbers 300-399.
3L1 Primary inductor.
10 TIG module. Wire numbers 1000-1199.
10AP1 TIG board. See the description on page 13.
10EV1 Fan, 24 V DC. See the description of 20AP1:2 on page 24.
10TV1 HF transformer. See HF generator on page 13.
15 Power module. Wire numbers 1500-1699. See the schematic diagram
and description on page 15.
15AP1 Power board. See the description on pages 16 - 20.
15AP2 Filter board with rectifier modules. See the description on page 21.
15AP3 Current sensor. See the description of 20AP1:8 on page 28.
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Component Description
15C1, 15C2 Smoothing capacitors.
15D1, 15D2 Rectifier and freewheel diode modules. Each module consists of two
diodes.
See page 46 for assembly instructions for the diode modules.
15EV1, 15EV2 Fans, 24 V DC. See the description of 20AP1:2 on page 24.
15L3 Inductor.
15TM1, 15TM2 Main transformers.
20AP1 Controller circuit board. See the description on page 23.
CAUTION !
STATIC ELECTRICITY can damage circuit
boards and electronic components.
S Observe precautions for handling electrostatic-
sensitive devices.
S Use proper static-proof bags and boxes.
ESD
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MechTig 3000i
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DESCRIPTION OF OPERATION
This description of operation describes the function of circuit boards and other components
in the power source. It is divided into sections, numbered to correspond to the circuit board
numbers and divisions into function blocks.
2AP1 Interference suppressor board and main rectifier
Circuit diagram, 2AP1
R7, R8 and R9 are varistors that clip the voltage peaks exceeding about 1100 V. The
varistors do not conduct when the voltage is below 575 V AC RMS, this corresponds to a
peak voltage of 810 V.
Main rectifier 2BR1 is fitted on the heat sink. See the fitting instruction on page 46.
Component positions, 2AP1
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10AP1 Tig board
Circuit diagram of the TIG functions
10AP1:1 Power supply
42 V AC is supplied from transformer 2TC1.
10AP1:2 Communication with the control board
The processor on circuit board 20AP1 controls the relay RE2 that supply 42V
AC to the HF generator.
10AP1:3 Gas valve
This function is not used. The gas valve is controlled by MechControl.
10AP1:4 HF generator
The HF starting device at 10AP1 is controlled by the processor on circuitboard
20AP1. It is activated during the starting sequence until the arc strikes, or for a
maximum of 0.7 seconds.
The voltage on the primary side of HF transformer 10TV1 is about 550 V. The
secondary voltage is about 11 kV if a 4 metre long welding torch is connected.
If the welding torch is 16 metre long, the HF spark is about 8 kV.
Due to electromagnetic interference regulations, the energy in the HF ignition
spark is limited, and so the HF spark weakens with increasing length of the
torch. The HF ignition is satisfactory for welding torches up to 16 metres.
10AP1:5 TIG torch switch
This function is not used.
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10AP1 Component positions
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15 The power module
The power module converts the rectified 3-phase 400 V to the welding voltage. It consists of
a dual forward inverter, operating at a switching frequency of 2 x 40 kHz.
The IGBT modules IC3 and IC8 and the diode modules 15D1 and 15D2 are all mounted on
a heat sink.
WARNING!
The power module is at mains voltage.
0 V in the power module is connected to mains voltage.
Schematic diagram of the power module
If circuit boards 15AP1 or 20AP1, are replaced, the gate pulse waveforms must be checked
afterwards and the machine must be soft-started. See page 42.
See the instructions on page 46 concerning mounting of the components on the heat sink
(15AP1 with IC3 and IC8, 15D1 and 15D2).
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15AP1 Power board
The power board carries the charging circuit, the gate driver circuit, the switching circuit and
the overvoltage and undervoltage protection circuits.
WARNING!
Dangerous voltage - mains voltage. Never make any measurements on this board
when the machine is connected to the mains supply.
On pages 38 and 42 there are instructions on how to check the power board.
15AP1:1 Internal power supply
The board is supplied with 24 V AC from winding S1 on auxiliary transformer
2TC1.
CAUTION!
The winding S1 must never be mixed-up with the other 24 V winding on this
transformer since 0VA has a galvanic connection to the mains supply.
15AP1:2 Temperature monitoring
NTC IC3 and NTC IC8 are fitted inside the IGBT modules IC3 and IC8.
The temperature monitoring circuit operates when the temperature exceeds
110 _C and resets at 50 _C.
See also the description and principal diagram on page 27.
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15AP1:3 Overvoltage and undervoltage protection
WARNING!
Dangerous voltage. Mains voltage on circuit board 15AP1 when
connected to the 400 V supply.
0VA on power board 15AP1 is connected to the mains supply.
0VA is galvanically isolated from 0V.
The overvoltage and undervoltage protection generates a fault signal if the
voltage across capacitors 15C1 and 15C2 falls outside the permitted interval of
300 - 715 V DC, which is equivalent to a mains voltage of 212 - 505 V AC.
In the event of a fault, the display panel will show event code 5.
The fault state will not be reset until the DC voltage is within 400 to 650 V.
During normal operating conditions, the voltage between pins CN08:6 and
CN08:7 on circuit board 15AP1 is about 0.1 V. Optocoupler IC4 is used for
galvanic isolation of the voltage monitoring circuit from control board 20AP1.
A break in any of the conductors to/from 15AP1, as shown in the diagram
above will result in a fault state.
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15AP1:4 Charging circuit
When the mains power supply is turned on, smoothing capacitors 15C1 and
15C2 charge up via resistors R15 and R16.
When there are gate pulses present at pulse transformer TR2, transistor Q19
pulls the SHDN (shutdown) signal to 0VA.
PWM circuit IC2 generates gate pulses to the thyristor in IGBT module IC8, the
thyristor short-circuits resistors R15 and R16.
Resistors R17 and R18 are potential dividers and discharge resistors for 15C1
and 15C2.
The PWM circuit generates a reference voltage +5.1 V, this is used by the
over/under voltage and temperature monitoring circuits.
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15AP1:5 Gate driver stages and switching circuits
WARNING!
Dangerous voltage - mains voltage. Never measure the gate signals when
the power source is connected to the mains supply.
The gate pulse frequency is 40 kHz. See page 42 for screen traces of
waveforms and measurement instructions.
Transformers TR2 and TR3 are gate driver transformers for galvanic isolation
of the drive circuits from controller board 20AP1.
If an IGBT module has failed, both the power board and the modules Q3 and
Q8 must be replaced. Failure of either module always subjects rectifier bridge
2BR1 to a high current surge, which substantially reduces its life. We therefore
recommend that the rectifier bridge should also be replaced if the modules
have failed. See page 38 for instructions on checking the IGBT modules.
The IGBT modules and circuit board 15AP1 must be mounted in accordance
with the instructions on page 46.
15AP1:6 Fan control
See 20AP1:2 on page 24.
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15AP1 Component positions
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