Service manual FastMig Pulse power sources version 1.1
Contents
1. HT3 n N v N 18 gn w 0602991 Xx LI wee S Y PERS AX 3 Dra ez gt LJ amp n apa gt w gt euch 7 bz se mt E 14 27 tu raw S z Lexi ET T 4 aR9 3 en MT gr 8 mur LE N Mso e ra AR229 r 1284 F LENE ee o R280 4 w R25p n201f n A n26p 3 a R2B5 fi 0n cigg 94 ow LH LEE Arias Z m j mg L m n m M 4 i nu s mt RUE Ir mi Bos s E net T T e B Ir 1311111 e o 8756611 2 gt AZO 321 gt wsmRIEEB a VERE FRI QU e AREA HERE HH I H9 15V H8 FPGA Configuration H10 5 3V H11 1 2V H1 Microcontroller state H13 2 5V H2 H3 Data communication H14 43 3V a f bss lid nhl VY YR RR EX Rupi E a KEMPPI The Joy of Welding Processor card 002 connectors 1 20 pin box JTAG X11 1 6 pin wire to Not connected header production programming board es ee xi2 MaTEN Lock2 Spare ADD not connected 40 pin box Connects gate driver and BEEN Shunt header processor board Secondary voltage ee X9 1 6 pin wire to Current transformer ac X9 2 MATE N LOCK2 Machine size jumper J1 MEE EE EN2. m lt mn w E 2 O lt 10 A 5 xa lt Water Caaler xDa5 5V D sa E LI E a aa z m GND A DATA B 892 Primary Current 15 END D gt ANALOG 5AaV C 00 gt 24 END Haa Y Ov T LED 1 GJ Power QN LED S OE SI S S S S SN S S S SN SN S SNI S S SN SN SNI SNI S XE S XE SN NI SI SN SN SN XE SASS 1D ED D Il WN IGET GATE G IGET_GATE_8 LJ LJ Lj LB L Lu Lu LJ LJ Lj LJ Lj L L LO Lj Lj L LO L3 LJ Lu Lj Lj LD L3 L LJ L3 Lj LJ L3 L3 _ AL ARM SHDN PwM FPGA_ecanf ig dane E ANILON Z OFF gt FAN2 ON OFF G OvVT PTC CLLI Fault CLLI AD CHI CLU_AD_CH2 gt CLU_ON OFF G 4 GND EAN TX GND gt Remate Cantral G z 2 3 i ui i m 1 ql 1 1 m au i DL IG T RJ x Qe i lp lt mr i amp i i Os i Us i i 6 X004 N i Os s6 mv 7450 i fin lt i psu x lis RCOGI HEN mc ES OE mid CES i _ x z xz N mm mm QOS g Machine size jumpers Fas tMigPulse Main circuit diagram PIAT ViAn TARRA 6 3 2008 VALM QHJE KES 54 002 W a 3 5 7 A
3. Kemppi IGBT testing by Kemppi IGBT tester e Disconnect and X4 connectors IGBTs 1 and 2 e Connect C1 3 to Z002 X1 DC link positive e Connect E2 2 to Z002 X3 DC link negative e Connect B1 4 to X4 4 IGBT 1 gate control positive e Connect B2 6 to X4 6 IGBT 2 gate control negative e Connect C2E1 1 to X4 1 point between IGBT 1 and 2 IGBTs 3 and 4 e Keep C1 3 and E2 2 connected as above e Connect B1 4 to X3 6 IGBT 3 gate control positive e Connect B2 6 to X3 4 IGBT 4 gate control negative e Connect C2E1 1 to X4 1 point between IGBT 3 and 4 Only when triggering by buttons TR1 and TR2 LEDs should illuminate If LEDs don t light or are lit without triggering the IGBT module may be faulty Double check connections to be sure KEMPPI The Joy of Welding Replacing the 2001 card FastMig production family has a soldering IGBT module and it is not possible to change it separately Only reliable way to replace the module is to change the whole Z001 main circuit card Compound applied prior to spreading Electrolube HTC NON Silicone heat transfer compound EHTC10S is supplied for use during equipment repair The tools and workshop premises used during this type of work must be kept clean and free from dirt and dust Even very small particles 0 050mm between the surfaces could increase the gap between the module an the heat sink causing overheating and damage Make sure that these wires
4. eK The Joy of Welding Service manual FastMig Pulse power sources version 1 1 Heleased 30 12 2009 Updated 13 01 2010 WARNING 400VAC 50 60Hz and 5 0VDC 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 still exist after the removal of the input voltage Wait at least one minute for the capacitors to become discharged The device may be repaired only by a person legally authorized to perform electric Work KEMPPI The Joy of Welding Electrostatic Discharge Electrostatic discharge ESD is phenomenon that occurs almost everywhere and often At its most powerlul 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 aga
5. are NOT trapped during the re assembly of the Z001 to the heatsink Heat sink transfer compound is to be spread in an even layer of approximately 0 1mm onto the module Then the module should be immediately mounted onto the heat sink this minimizes the possibility of any contamination dirt etc getting between the components The M5 fixing screws are tightened stage 1 to 0 5 2 Nm After few minutes the module fixing screws can be finally tightened stage 2 to a torque of 3 Nm Note Input rectifier is tightened to 2 Nm Compound Tightening sequence spread Stage 1 All four screws to 0 5 2 Nm correctly Stage 2 All four screws to 3 Nm KEMPPI The Joy of Welding Low voltage test Low voltage test gives basic information where machine has fault Machine will be fed from auxiliary transformer secondary winding to control blocks and via primary winding to DC link Because of reversed power feeding and current limited to 5A there is lesser possibility to burn more components Also after replacing components it is recommended to start from low voltage test Low voltage test is a three stage test First stage will test only the A001 A002 and P001 cards Second stage will test the same cards and the CAN bus voltage there is possibility to connect wire feeder Third stage test all the above and the DC link X2 Testing First stage Current must be limited to 5A in workshop PSU Disconnect X2
6. DC link voltage Soldered wire Teen voltage X8 X15 Soldered wire IGBT gates and emitters Soldered wire Current transformer secondary Soldered wire Current transformer secondary Soldered wire 400VAC Aux transformer Soldered wire 400VAC to Aux transformer KEMPPI The Joy of Welding Capacitor 2002 layout and connectors DISCHARGE RESISTORS X1 m 20 LINK 5 DISCHARGE RESISTORS KEMPPI The Joy of Welding Connector pin Connector type T 4 Secondary rectifier 2003 layout and connectors FILTER CIRCUIT TIG INGNITION PROTECTION X1 X2 RC DAMPING CIRCUIT X3 X4 A 1 Bau Aa KEMPPI The Joy of Welding La E n Ln 2m a 2 oe a bg a x DN NI w um un L j k d Ea 4 EB NEAN Im i ME m r E El DIODE BANKS DIODE BANKS wm Other tests CONNECTORS CONNECTORS Here are several useful tests not mentioned before Machines three in connectors X13 X15 e are serial wired and any of them can affect thermal alert e Resistance should be 55 700 e Values measured in 20 Celsius degrees and may vary depending environment temperature e f machine is warmed up values may vary e Broken PTC has mostly hundreds of kilo ohms or no value at al
7. 2 __ Machine size jumper J2 2032 battery RTG battery holder WWW S Current transformer ac Machine size J1 1 Machine size jumper 2 KEMPPI The Joy of Welding Setup panel card P001 layout SEVEN SEGMENT m rs tB agile DISPLAY FOR MEMORY ees ALN Bienes CHANNELS E Tt 4i T i PULSE POTENTIOMETER FLATCABLE 35e CONNECTOR amp JE A L jl ARRA ci e 9758610 JUMPER CONNECTOR FOR FUTURE PURPOSES LCD DISPLAY MEMBRANE PANEL MICROPROCESSOR CONNECTOR KEMPPI The Joy of Welding Setup panel card P001 connectors PF65 X1 and P65 X1 CAN bus interfaces are identical Both Panels use CAN interface and KeBus protocol Se r t B i When panel starts panel software version number in in display during this period of any of the buttons are pressed all memory channel segments turn on and all LCD pixels are also turned on This function can be used to test the panel buttons and LEDs displays This test mode is only possible when panel is starting KEMPPI The Joy of Welding Main circuit card Z001 layout Z002 CARD CONNECTIONS IGBT MODULE INPUT RECTIFIER Z002 CARD CONNECTIONS GATE CONTROL CONNECTORS TRANSIENT SUPPRESSION DIODE EMI FILTER KEMPPI The Joy of Welding Main circuit 2001 connectors EN ERN x EN Soldered wire
8. 3 and X4 Measure twisted paired wires X4 X3 Meter should read approx 10kO Simple static test of A001 gate circuit set to diode function e Disconnect module gate leads X3 and X4 Positive test lead Negative test lead Meter should read approx 0 1 VDC Reverse the test leads and repeat the above tests the meter should read over the limit or OL KEMPPI The Joy of Welding IGBT tests Kemppi IGBT tester Kemppi IGBT tester is simple way to be sure that module is working Tester simulates DC link voltage and gate pulses and measures output voltage Tester can trigger two IGBTs at the same time one for positive and one for negative so it have to be connected two different ways to test the whole IGBT module Tester takes it power from two 9V battery This makes possible to have DC link voltage as high as 18VDC which makes measuring more reliable Kemppi IGBT tester buttons and connectors ON OFF switch owitches tester ON and OFF TR1 and T R2 Trigger buttons for gate controls LEDS ohows If output has a voltage C1 3 Emulates DC link positive voltage E2 2 Emulates DC link negative voltage B1 4 TR1 gate control signal positive B2 6 TR2 gate control signal negative C2E1 1 Pos Neg output voltage measuring oe Ee Tes o TR1 TR2 CONTROL Note Switching tester OFF saves battery life while not used OFF ON KEMPPI The Joy of Welding IGBT tests X1 X3 X4
9. and X008 connectors e Input 20VAC straight to A001 card connector X2 pins 1 2 or 2 If machine starts up control cards are working LED s lit P65 display on By pressing Menu button demo mode is available Note Power source gives bus error because there is no 38VAC to be rectified for the bus voltage 50VDC KEMPPI The Joy of Welding Low voltage test Testing Second state Current must be limited to 5A in a workshop PSU e Connect only X2 and input 20VAC to connector X2 pins 1 2 or 2 3 e Voltage goes to another secondary coil as 38VAC Wire feeder unit can be connected and all setups used Wire feeder can be triggered and wire feed speed adjusted If no wire feeder is connected P65 display show s Local loop If machine can start up control cards and CAN bus is working check voltage Testing Third stage Current must be limited to 5A in a workshop PSU e Input 20VAC to aux transformers connector X2 pins 1 2 or 2 3 Voltage goes thought secondary winding to primary side as 400VAC Voltage goes also to another secondary coil as 38VAC as above Machine starts up and DC link voltage can be measured Z002 X1 and X3 Note There can be over 400VDC in DC link Wire feeder unit can be connected and all setups used If machine does not start up or current goes to 5 limit there is probably a short circuit somewhere in the primary Note Wire feeder can not be triggered power source tak
10. certain current is set U 0 04x I 20 CV MIG MAG machines curve s secondary current can be calculated when certain voltage is set U 14 0 05 Voltage current have to be set for nominal curve correct output power E g when making PTC test there must be right values to meet duty cycle specified in technical specification Most useful tests to be made with a load bank are to check maximum and minimum current and to check if machines voltage current adjustments and control electronics work KEMPPI The Joy of Welding Load bank test Fastmig pulse power source can be tested without wire feeder in local loop mode In local loop mode it is possible to have a secondary current up to 100A adjust current remote controller have to be connected Note Local loop mode does not include MMA nominal curve so it is not possible to weld by MMA Example 1 Constant current test local loop mode e Turn the machines main switch OFF e Connect machine to load bank e Turn the machines main switch ON e Connect remote controller to power source n panel P65 can be seen title Local loop e Add some load to load bank e When current starts to flow raise current to desired level this example uses maximum value 100A e Be fast when increasing load there can exist arc inside the load bank switches Measure current by clamp meter and voltage by DMM e Values can be seen also in panel P65 Current should be 100A and voltage can be calculated fr
11. ding or writing to memory Machine can not write to feeder memory card check the cables and connections possibly broken control memory card NO BUS Panel can not connect to the CAN bus Check the flat cables Check the panels KEMPPI The Joy of Welding PRIMARY CHOKE AUXLIARY TRANSFORMER Z003 SECONDARY RECTIFIER DIODES SECONDARY CHOKE SECONDARY EMC FILTER KEMPPI The Joy of Welding Construction right side WILLIS rg LE 1 In a ir Lu L d amp MAIN TRANSFORMER Construction left side IGBT DRIVER CARD A001 MAINS CONNECTOR AND VARISTORS PANEL CARD P001 ss Nen xe d EA hat V Sq d MAINS j eG SWITCH WATER COOLER POWER CONNECTOR Z001 MAIN CIRCUIT BOARD AND Z002 DC LINK SHUNT RESISTOR CAPACITOR BOARD PROCESSOR CARD A002 KEMPPI The Joy of Welding 25 mm taraid m 2 raunds C c zl GNYE xBoB 400v TOB2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 LD D J CD Ul U N 7 NC CAN data CAM r xd CAM txd 4 LI ED FD CD CD CD ED CD PD ED D CD CD CD FD CD D LD FD Ch CI WN 24V Cae Fani 24V IIW Maa2 Fan2 24V IW 24V p Gaal XIB XIZ X24 x21 umuv ium m m m m CLULFAULT GND ELLU AD CHI CLLU AD CH2 ON OFF mu amu tn
12. e values Primary Secondary 5MO Primary Ground 2 5MO Secondary Ground 2 5MO Ground is located in machine chassis If values are much less than expected there might be insulation break down and it should be inspected Note Wire feeder has only Secondary Ground point to test Primary Secondary 5MO e Phases must be connected together and Dix connectors must be connected together e 5001 switch is set ON KEMPPI The Joy of Welding Safety test Primary Ground 2 5 MO e Phases must be connected together e 6001 switch is set ON Secondary Ground 2 5MO e Dix connectors must be connected together e 6001 switch is set ON KEMPPI The Joy of Welding General troubleshooting Always try to get a detailed description of the complaint This troubleshooting guide is to remind the service technician to check the simple things first a visual Inspection can often help with fault finding If visual damage can be seen replace all broken parts If everything looks normal or broken parts are changed it is recommended that a low voltage test is carried out Disconnect the machine from the input supply and remove covers th
13. en check Are there any breaks in the cables e Are the cables correctly connected e Are there any loose components e Are mains fuses circuit breakers OK amp correct valves e Any signs of burning or arching Connect the machine to the mains input supply and check e 15 there a stable three phase 400VAC input inside the machine e Is the machine in shut down mode Are the settings OK KEMPPI The Joy of Welding Diode tests Ensure that the machine is disconnected from the mains input supply Use multimeter with diode check function to test machines input rectifier and secondary rectifier Remember to test forwards and backwards the following Input rectifier Use positive test lead to check input terminal side and negative test lead X1 DC link T ELA to check DC link side S001 switch must be set ON Input terminal positive 1 X1 L2 X1 11 612 L3 Change test leads and repeat tests If diodes OK There should be threshold voltage approx 0 5VDC forward biased condition or over the meters limit reverse biased condition If short circuit close to OVDC KEMPPI The Joy of Welding Diode tests Use multimeter with diode check function to test machines Input rectifier and secondary rectifier Remember to test forwards and backwards the following FOUR BANKS OF DIODES Secondary rectifier POSITIVE OUTPUT RAIL Use positive test lead to check posi
14. es too much power and machine shuts down Connect 20VAC KEMPPI The Joy of Welding Gate driver card A001 layout POWER SUPPLY m LES o a E za T a Te 24 L Cag Li af hy FUSES 2 x 3 15A IGBT DRIVER n gt 4 PANEL CONNECTOR COOLING FAN S CONNECTORS _ OVERHEAT SN PROTECTION SYSTEM BUS PTC s get aie INTERFACE CONNECTORS PROCESSOR CARD A002 CONNECTOR POWER ON LED AND OVERTEMPERATURE LED T CONNECTOR KEMPPI The Joy of Welding Gate driver 001 LED info A001 Gate driver card has several LEDs to show basic information of cards functions and states LEDs H1 H4 H5 and H6 shows if IGBT can have control signals LEDs H7 and H8 show if there is feeder unit connected and if data is available in CAN bus LEDs H2 and H3 shows if there is needed control voltages from cards own PSU LAB46 zl oe j ALLAI 1 A d v20 2 e LI M LI V25 C28 C25 o te 4 ae x we Sy I une vides T eu x o I im toh In 5 E e ML Top R34R33l E 0 34 C3 ve gt R88 R84 C46 R7 9TP4 9 v m 2 R82 CSE R83 hc H1 IGBT gate pulses H7 Remote control unit connected H2 45V H4 IGBT gate pulses H8 Data communication 15V H5 IGBT gate pulses H6 IGBT gate pulses KEMPPI T
15. he Joy of Welding Gate driver 001 connectors Connector pin Connector type Tab terminal 6 3mm DC link voltage X2 2 MATE N LOCK 20V auxiliary voltage ground X2 1 3 pin wire to board 20V auxiliary voltage BEEN 20V auxiliary voltage 6 pin wire to board IGBT emitter Connector pin Connector type XA 6 pin wire to board IGBT emitter X4 2 MATE N LOCK Not Connected te _ te _ X5 1 2 pin wire to board Switched Fan M002 X5 2 MATE N LOCK2 Fan M002 24VDC he Joy o Welding Connector pin X6 1 X6 2 Connector pin X9 1 Connector type 2 pin wire to board MATE N LOCK2 40 pin box header 16 pin box header with locking latches Connector type 12 pin wire to board MATE N LOCK owitched Fan M001 Fan M001 24VDC Connects gate driver and processor board Panel board connector System bus DATA E Gate driver card A001 connectors Auxiliary voltage ground Not connected EL MATE N LOCK Auxiliary voltage ground X13 1 2 pin wire to board PTC primary heat sink profile Spare supply voltage 5 X13 2 MATE N LOCK2 PTC primary heat sink profile a Puma X14 1 2 pin wire to board PTC main transformer Over temperature LED 5VDC PTC X14 2 MATE N LOCK 2 Over temperature LED switched main transformer Gnd Power oN LED switched 5VDC X15 1 2 pin wire to board PTC secondary P
16. inst 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 circult 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 and abridged from Kemppi PRONEWS are labelled as such KEMPPI The Joy of Welding 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 multimete
17. ions because it might lead you to change the wrong parts KEMPPI The Joy of Welding Safety test Safety test should be carried out before opening machine or connecting it to the mains power supply to protect the service technician All the new machines are tested in the factory but it is recommended to repeat these tests before and after service repair work The safety test is divided into two parts protective earth PE conductor continuity and insulation resistance measuring PE conductor continuity measuring PE continuity is measured between protective earth conductor and machine chassis Resistance should be less than 100mQ 0 1Q Below is a calculation to determine the desired test voltage R 100mQ I 15A U U RXI 0 IQXx15A 1 5V When using 15A as the measuring current the voltage should be less than 1 5V between PE conductor and machine chassis Then the resistance must be less than 100mQ The protective conductor continuity measuring can be done with equipment similar to that shown in these pictures Easiest way to measure PE conductivity is to have special tester like Megger PAT32 It tests conductivity using an input current of 25A so voltage should be less that 2 5V KEMPPI The Joy of Welding Safety test Insulation resistance measuring Insulation resistance is measured using 500VDC This have to be made in three points Depending of measuring point there have to be minimum resistanc
18. l Cooling fans e Cooling fans operating voltage is 24VDC max current 458mA e When cooling fans start ground is switched If cooling fans are not working they might be short circuited or A001 card has failure in control logic Note There is delay in cooling fan start up BE PLUS ne CAN bus voltage 0OVDC e Check if there is aux voltage 38VAC to aux rectifier e Check if there is CAN bus voltage 50VDC in rectifiers output 4 e Check if there is burned fuse in back plate fuse socket 6 3A DC MINUS CAN bus voltage rectifier KEMPPI The Joy of Welding Load bank test Load back test is used not only to simulate welding but also to check voltage current characteristics Load bank can be passive load with switchable power resistors or active with selectable voltage current curves If using passive load bank a multimeter is used for voltage and clamp meter for current measuring Some passive loads has integrated meter for easier testing Active loads have mostly meters because of their special construction its control electronics needs values to adjust active load To be sure load bank is adjusted correctly a calculation is required for voltage or current to have desired nominal curve Constant voltage e g MIG MAG and constant current MMA have different voltage current values and they can be calculated from following formulas CC MMA machines curve s secondary voltage can be calculated when
19. om following equation 100A 7 0 04 20 04 100 20 4 20 24V To get required voltage increase or decrease load in the load bank Before disconnecting the load decrease machine current to minimum to avoid unnecessary arc inside the load bank switches KEMPPI The Joy of Welding Load bank test To make MIG MAG load bank test for Fastmig Pulse wire feeder must be connected to the power source Example 2 Constant voltage test MIG MAG e Turn the machines main switch OFF e Connect machine to load bank Turn the machines main switch ON be sure machine start is OFF open e Add some load to load bank e Adjust machine voltage to desired level this example uses 22V e Start the machine Measure current by clamp meter and voltage by DMM e Values can be seen also in panels P65 and PF65 Now voltage should be 22V and current can be calculated from following equation U 22V Le 0 05 _ 22V 14 9 160A 0 05 0 05 To get the required current increase or decrease load in the load bank Before disconnecting the load put machine start to OFF to avoid unnecessary arc inside the load bank switches KEMPPI The Joy of Welding Error codes Err 1 Power source not calibrated or calibration data cannot be Restart power source if the problem continues after multiple startups check the power read source control cards Err 3 Over voltage mains supply Check the main voltage Err 4 Over heat power
20. ower ON LED Gnd heat sink profile Spare supply voltage 24V X15 2 MATE N LOCK2 secondary heat sink profile Auxiliary voltage ground X17 1 6 pin wire to board Cooling unit supply voltage 24V X17 2 MATE N LOCK2 Cooling unit error signal 0 active O OS Cooling unit analog input Cooling unit analog input Cooling unit on off signal 5VDC on Plated PCB hole Chassis ground KEMPPI The Joy of Welding POWER SUPPLY PRIMARY CURRENT SECONDARY VOLTAGE AND CURRENT MEASUREMENT NS 7 E CIRCUITRY aum ee PRIMARY CURRENT TRANSFORMER AND MACHINE SIZE JUMPER CONNECTOR SECONDARY VOLTAGE AND CURRENT SHUNT CONNECTOR 875881 0 mem FPGA HER s duu REPE id a B B Bs E gu aJ PT D KEMPPI The Joy of Welding qur 5 us Z d n E we LES GATE DRIVER CARD A001 CONNECTOR BOWEB JTAG CONNECTOR MICROCONTROLLER REAL TIME CLOCK BATTERY CR2032 Processor card A002 LED info A002 processor card also has LEDs for easy card level checking H9 H14 show different voltages in card Led H8 shows if FBGA configuration is executed successfully LED should illuminate H1 shows microcontrollers operation state and H2 H3 shows if there is activity in data communication lines w 3 f r TA i a ae Fille du L MITES y wr F zt gs ne es pi nas T
21. r 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 Torque wrench with torx heads Cable ties Testing equipments Digital multimeter True RMS 800VDC 600VAC for safe operation Regular workshop power source with 20VAC output or Kemppi Multipower 22VAC PE tester 15 25A e g Megger PAT32 Insulation resistance meter 500VDC e g Megger PAT32 Useful extra tools Kemppi IGBT tester Digital oscilloscope 10MHz or greater KEMPPI The Joy of Welding General service procedure It is recommended that a systematic method is used on all repair or maintenance work each repair is a special case and should be handled as required but by following a routine less mistakes and safety issues will occur Here is an example of a general routine 1 Safety test 2 General troubleshooting 3 otatic tests 4 Repair work 5 Low voltage test 6 Load bank test 7 Safety test 8 Test welding Note Safety test must be done before and after repair to be sure machine is not possibly dangerous for user or service man Remember always use recommended fuse sizes in service workshop equipment to be sure of safety issues Always try to isolate failure to certain blocks This manual has several tests to make conclusions and to isolate the problem Be careful not to make assumpt
22. source Do not shut down the machine cooling fans will cool the machine Check the ventilation If cooling fans are not running check the power source connections and voltages Err 5 Auxiliary voltage 15VDC too low control card led H9 15VDC Main supply voltage is too low or aux supply faulty check the main aux supplies Can show up also if one of the mains phases is missing Note Only one of the three phases can affect this error if missing one where aux transformer is NOT connected Err 8 FPGA not configured Restart the power source if the problem continues after multiple startups check the power source control cards Err 27 Water cooler error Check the water cooler connections and functions For more details check the cooler service manual Err 42 WF Motor over current warning delayed fault at 3 5A Check the gun and the consumable parts Err 43 WEF Motor over current error delayed lock at 5A Check the gun and the consumable parts Err 45 Gas guard alert only if gas guard connected and activated Check the shielding gas gas guard and all the connections Err 50 Function is not activated If function is required please order proper license Err 62 Power source not connected or not identified Check the intermediate cable Feeder is powered up but it can not identify the power source Err 81 Welding program not found If welding program is required please order proper welding program and license MEM ERR Error while rea
23. tive output side and negative test p lead to check four banks of diodes p LI Im Positive output rail Bank 1 Positive output rail Bank 2 Positive output rail Bank 3 Positive output rail Bank 4 Change test leads and repeat tests There should be threshold voltage approx 0 335 VDC forward biased condition or over the limit OL reverse biased condition If meter reads close to OVDC diodes are 1n short circuit KEMPPI The Joy of Welding IGBT tests IGBT module be tested two different ways Easiest and fastest 15 to use DMM to have some info about IGBT module Another way is to use Kemppi IGBT tester to have exact data IGBT testing by DMM To test the modules four IGBTs individually disconnect the gate leads and X4 from the A001 card set the DMM to diode check function use the chart below X4 X3 IGBT number Positive test lead Negative test lead IGBT 1 gate lead X4 1 Z002 X1 IGBT 2 Z002 X3 Gate lead X4 1 IGBT 3 Gate lead X3 3 Z002 X1 IGBT 4 Z002 X3 Gate lead X3 3 The threshold voltage should be approx 0 335VDC forward biased Reverse the test leads and repeat the above tests the meter should read La ch over the limit or OL reversed biased EE oes e aF Nx sq L EH S KEMPPI The Joy of Welding IGBT tests IGBT gate lead testing set to resistance function e Disconnect module gate leads X
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