Service Manual - Rapid Welding and Industrial Supplies Ltd
Contents
1. T ali ans js oar L H x Ex ea IGBT gates mei Eee FN PS E x Ka _ m m on Power stage Current transformer 8 F F D F The Joy of Welding Main circuit card Z001 X19 X21 X16 X17 X148X49 X20 X24 X15 X14 X11 X6 X10 37 X13 X12 X36 X9 X8 X20 X18 X17 X40 X16 X41 x3 X29 Connectors X2 Z001 connectors signals X4 X1 X5 X7 _X13 IGBT gates and emitters X14 IGBT gates and emitters X15 IGBT gates and emitters X17 X37 Auxiliary transformer X41 Auxiliary transformer V KEMPPI The Joy of Welding Main circuit card Z001 Operational measurings VIEW SCHEEH 17 VIEW SCHEEH 47 A 8 Main transformer T001 primary voltage IGBT gate pulses set values 50 A 16 5 V set values 50 A 16 5 V 12 The Joy of Welding Capacitor card Z002 Energy storage Discharging Connectors Z002 connectors signals The Joy of Welding Secondary rectifier card Z003 o 0 6 6 c 6 0 0 Rectifying Snubber Protection against HF 0 0 000 0 00 0 00 0 6 0 0 6 0 8 Connectors Xl Main transformer secondary X2 Maintransformersecondary Maintransformersecondary 4 Main transformer secondary X5 Secondarychoke X8 Secondary choke2. se a Operation of the J umpers J 7 J 8 Connector X11 on control card A001 Power sources 1 and 2 has to have different device numbers in the system Device number is given using jumpers 7 and J 8 as follows J 7 not placed J 8 not placed gt Device number 2 J 7 placed J 8 not placed gt Device number 13 7 not placed J 8 placed gt Device number 14 7 placed J 8 placed gt Device number 15 20 D q eh V KEMPPI The Joy of Welding Control card A002 Connectors m s a He aaa ike P cS 4 Fh i wr 4 Th X4 Ai TA ka TF E id r L 1 2 Connection to the panel card P001 Fuse The Joy of Welding Control card A002 Connectors A002 X1 X1 1 Connection to A001 X9 4 X1 Connection to A001 X9 10 A002 X2 X2 Connection to panel card Connection to 001 092 Connection to A001 X9 2 wo X4 12 X4 14 X4 15 The Joy of Welding Panel card 1 Main micro controller User interface buttons potentiometers display Connection to the A002 Connectors P001 X2 X2 Connection to A002 The Joy of Welding Control panel P1 2 P3 KEMPGOUGE P4 P5 Pl Left display gouging current or name of adjustable parameter P2 Indicator lights for the current area P3
3. 5 n The Joy of Welding Connection box Power source 1 KEMP GOUGE CONNECTION BOX Power source 2 Mains voltage is delivered to the Power Sources 1 and 2 through the Connection Box Main switch S001 disconnects power source from the mains and the varistors R001 protect power source from the low energy voltage spikes After main switch the voltage branches to power sources 1 and 2 Outputs of power sources 1 and 2 are connected in parallel in connection box and then connected to the output connectors Capacitors C002 C003 and varistor R003 in series with capacitor C001 reduce radio frequency interference and provide protection against TIG ignition spark 6 The Joy of Welding Power source 1 TB CONNECTION HDW L3 Li TO CONNECTION Im GHYE kug Sud 40a EMI 3686 dz CONTAOL EBUS TO POWER SOURCE 2 THROUGH CONNECTION BOK 1 BB TO CONNECTION t h g Ho 8 MEE Famn Fant Dake PIAT OUa TARE KEMP COUCE BH mem im EEMPPI POWER SOURCE 1 ALWOHIE Power source 1 is slightly modified version of FastMig KM 400 The main switch and output connectors are removed Secondary unit is replaced with KMS 400 secondary unit Control card A001 is modified version of KMS
4. Service Manual KempGouge ARC 800 Table of contents CT L ee ee ne s nmana mia T 3 Technical gate 4 Main circuit diagram eene 5 DOK u l E 6 0 DEVE Power Source 8 Main circuit Card 200100 I rrr Er RR igi 9 10 CONECO aee 11 0 12 Capacitor card 13 Secondary rectifier card 2003 14 Operational 0 15 Control card 0 01 16 Bonnae 17 18 Forme 19 Tamper Se UN ua 20 Control card 21 Belts L TERRE E 22 Panel card POOL M 23 ROW 24 uitia err NOTTE ee su s man 25 26 27 IGBT I 28 IGBT 0 29 00 30 31 The Joy of Welding General carbon arc gouging metal is removed by melting it with an arc and blowing the molten metal away from the object with compressed air A carbon rod is used as an electrode which can be either round or flat inshape KempGouge ARC 800 suitable for all types of carbon arc gouging 800 power source with control panel Power sources can be connected to the mains supply of 400 V 3 The whole system weight i
5. in the bus is using same code conflict Err 252 DLI data error 2 Err 254 DLI data communication error connection to other units has been interrupted maybe bad connectors or cable damages Err 255 DLI data communication error program update problem maybe a wrong program version etc Err 0 999 Unidentified error system bus has sent an error message not identified by the panel 25 M d The Joy of Welding Construction T002 Aux transformer 1 Choke CONNECTION BOX 002 secondary choke 1001 Main transformer eu V KEMPPI The Joy of Welding Construction A002 Control card P001 Panel card A001 Control card Z002 Capacitor card Z001 Main circuit card 27 w KEMPPI The Joy of Welding IGBT testing C2E1 1 lt 0 6 1 lt a T i F4 eu 4 m X9 2 5 2 N a The Joy of Welding IGBT replacing Mounting the IGBT to the heat sink The tools and premises used in this work must be clean and free of dirt and dust Even very small particles 0 050mm between the surfaces may increase the gap between heatsink and module causing overheating ans possible damage Heat transfer compound is to be spread in even layer of approximately 0 1 mm onto the module base Then the module should be immediately mounted on the heat
6. Right display gouging voltage or value of adjustable parameter P4 Setup button P5 Control knob gouging current adjustment factory reset User Setup menu Parameters FAC restore factory settings 1 Press Setup button P4 5s 2 Select by Control knob FAC ALL 3 Press Setup button 24 The Joy of Welding Error codes Powersource 1 50 User interface 201 250 DLI 251 255 Others 999 Err 2 Power source undervoltage new start up Err 3 Power source overvoltage new start up Err 4 Power source is overheated Err 11 Two units have the same address in the system bus Err 12 Data error on communication Err 13 Member of a wrong FastMIG family connected Err 14 Data communication problem between power source and auxiliary unit Err 15 Power source program updating method problem Err 21 Power source s control card 5 V aux Voltage too low Err 22 Power source s control card 15 V aux Voltage too low Err 23 Temporarily power source overvoltage Err 31 Power source calibration error Welding only possible with default values Err 205 Error on setting current Perhaps one of the power sources are not operational Err 221 Data error of the panel 1 Err 222 Data error of the panel 2 Err 223 Data error of the panel 3 Err 224 Data error of the panel 4 Err 225 Program updating problem Err 241 EEPROM is faulty Err 251 data communication error another unit
7. The Joy of Welding Secondary rectifier card Z003 Operational mesurings X003 machine pole Trig Probe 10 1 5 VIEU SCREEH 37 Voltage after secondary rectifier card 7003 set values 50 A 16 5 V The Joy of Welding Control card A001 X2 E E 5 TEs 1 amp m d I ba E ig E Ep PL i i k T LE M o mm 2 X1 sit ur 1 n 3 anf n M i ki 4 1 X8 X10 Microcontroller PWM circuit Secondary voltage measurement Secondary current measurement IGBT drive Auxiliary power supply Machine size jumpers J 1 2 Primary current limit jumpers J 3 J 4 J 5 Operational jumpers LED s s k t t R The Joy of Welding Control card A001 Connectors A001 1 1 DC link voltage A001 3 IGBT emitter IGBT emitter IGBT gate E 11____ X93 0 0 0 00 000000000 XIT 00 0 00 00000 X98 0 0 050 0 00 08 XII 0 0 0 0 0 0850 0 508 X9 12 A001 X9 2 System bus DATA B X005 System bus DATA B X006 50V X005 50V X006 X005 X006 9 8 Analog DATA X005 9 9 Analog DATA X006 X006 9 11 GND X005 9 9 gt lt gt lt NJ I c CJ 25 gt lt gt lt gt lt gt lt lt WO The Joy of Weldin
8. control card The purpose of A002 is to provide operating voltage and interface to the system bus for the panel P001 7 The Joy of Welding Power source 2 TO CONNECTION BLX La Li TO COMMECTION BOW Im GHYE TO CONNECTION MEE Famn Fant Dake CONTAGQL BUJ PORT OUa TARE TO POWER 9DURCE 1 KEMP COUCE TAARA mamm THH LIGH CONNECTION BOX POWEA SOURCE 72 Power source 2 is slightly modified version of FastMig KMS 400 The main switch and output connectors are removed Control card A001 is modified version of KMS control card Second system bus connector is removed from the back panel and is used to connect power source 2 to power power source 1 This connection is done through connection box Second system bus connector is leftto the front panel This connector can be used to update software in the system 8 s I The Joy of Welding Main circuit card Z001 EMI filtering Three phase rectifier V6 Switching ON transient suppression Power Stage Current transformer T1 4 v KEMPPI The Joy of Welding Main circuit card Z001 DC link Switching ON m transient supression T Connection box IN lif EMI Filtering Three phase rectfier E all a as 3s B zt 4 2 LR H DC link d n x
9. ctor B Contact body 12 poles female 9770453 pins 2 pcs male 9770462 Connector C Plug 6 poles male 9770458 pins 2 pcs female 9770463 Connector D Plug 15 poles male 9770460 pins 1 pcs female 9770463 Electric wire amd mi T gt 2 52 2 el I 2 20 4 D PS2 A1 X9 Connections 2 8 4 C11 A001 X9 A002 X1 4 5 5 10 4 A002 X4 12 2 The Joy of Welding
10. g Control card A001 Connectors A001 X10 X10 1 10 2 2 To connection box Us Le 10 11 GND Machine size jumper 1 10 12 GND Machine size jumper 2 A001 X11 Device number jumpers 8 Device number jumpers A001 X13 TC Rg 101 Z001 TC Rg 101 Z001 1 13 2 EE I 2 2 70 0 A001 X14 TC 101 1 TC 101 1 14 14 1 2 EE A001 X15 15 1 PTC Rg 201 4003 X 15 2 PIC Rg 201 23 16 9 H001 green led power on 16 10 H001 24V The Joy of Welding Control card A001 Operation of the LEDs on control card IGBT gate pulses IGBT gate pulses IGBT gate pulses Data communication Micro controller operation Micro controller operation H1 H4 Indicate the existence of the gate pulses H5 H6 Indicate that auxiliary voltages exist 5V and 15 If these Leds are not lit when the power source is switched on first thing to do is check if control card fuses are OK H8 Indicates that there is data communication taking place through the system bus when it is lit H9 H10 Indicate state of the microcontroller In normal situation both leds should be lit The Joy of Welding Control card A001 Jumper settings ais E 2 PES E LUN 9 a lt be TE E La 68 1 P s g 2 2 amame ape off eec r ne P ARBET ED d FA Y W l E
11. s 115 kg with the transport unit which enable easy moving from one job to another The Joy of Welding Technical data KempGouge ARC 800 Connection voltage 3 50 60 Hz Rated power Primary current Connector cable Fuse recommended Idle power Efficiency Power factor Load capacity at 40 C Current adjustment range Open circuit voltage Gouging carbon Recommended pressure of the compressed air Storage temperature range perating temperature range Degree of protection Dimensions without with transport unit Maximum load of lifting lug 50 ED 100 50 EDI 100 EDI 50 ED 100 ED Length Height Weight 400 V 400 V 2096 44 35 kV 65 51A HO7RN F 4616 16 63 A delayed 120W 0 90 0 90 800 A 44 V 600 A 44V 20A 800 50V max size a 13mm 500 700 kPa 5 7 bar 40 0 20 4 IP235 390 700 mm 230 660 mm 885 1 400 mm 94 115 kg 200 kg V KEMPPI The Joy of Welding Main circuit diagram POWER SOURCE 1 Power source 1 KEMP GOUGE Baa CONNECTION BOX 4 Connection box Power source 2 SOURCE 2 Kemppi KEMP Gouge 800 power source is basically one FastMig KM 400 referred power source 1 and one FastMig KMS 400 referred as power source 2 power source connected in parallel Mains voltage is delivered to the power sources 1 and 2 through Connection box which also contains output connectors of the power source
12. sink in order to minimize the possibility of dirt getting between the components Firts all the M5 type screws are tightened 0 5 2 NM After a few minutes the module can be tightened into the torque of 3 NM The Joy of Welding Testing cable connection low voltage test Testing cable makes possible to test power sources separately Notice you got an error code 205 make factory recall settings from machine setup Power source PS 1 1 Disconnect Control Bus connector X005 from PS2 7 way amphenol left corner inside P S2 2 Disconnect cooler fans from both of power sources 3 Connect Kemppi Multipower 22 VAC to control card A001 X2 1 2 after testing power source 1 connect all connectors back as original connections Power source PS 2 1 Disconnect jumper s from A001 X11 device number setting 2 Disconnect cooler fans from both of power sources 3 Disconnect PS1 connectors A002 X4 A002 X1 4 Disconnect PS2 connector A001 X9 5 Connect Test Cable connect connector A to PS2 A001 X9 connect connector B to PS2 A001 X9 baum connect connector to PS1 A002 X1 connect connector D to PS 4 6 Connect Kemppi Multipower 22 VAC to PS1 control card A001 X2 1 2 after testing power source 2 connect all connectors back as original connections 30 The Joy of Welding Testing cable connection Necessary parts Connector A Plug 12 poles male 9770459 pins 5 pcs female 9770463 Conne
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