Service manual - Rapid Welding and Industrial Supplies Ltd
Contents
1. Kempomig 3200 Kempomig 4000 During startup the wire feeder detects the power source size based on the voltage level at E line When the arc is ignited the power source pulls down the voltage in E line which gives an ar on signal to the wire feeder This arc on signal can be used for different kinds of mechanization purposes ET h e Joy of ell Voltages in the H line of the control cable between the power source and the wire feeder Az aT HIGH 10 0 LOW 0U 500ms5 Trig AS Probe 10 1 On MMA the wire feeder unit starts the power stage and develops an analog set value voltage of 0 10 V HIGH 380U LOW 0U 500ms5 Trig AS Probe 10 1 ET aa ER Es Probe 10 1 Post current time minimum 40 ms Post curren time medium 340 ms Post current time maximum 760 ms On MIG MAG the wire feeder unit starts and stops the power stage accoding to the gun switch and develops the analog set value voltage 0 10 V and post current time T hc Joy of W e d i n o CSSA Voltages in the I line of the control cable between the power source and the wire feeder MIG MAG dynamics 0 MIG MAG dynamics 9 On MIG MAG process the voltage in I line is approx 0 5 3 2 V depending on the dynamics setting Note that when welding with 1 MIG the dynamics setting is optimized according to the filler material and gas combination in use so the adjustment range depends on the chosen 1 MIG program MKEMPPI ET h e Joy of W e2. R160 Crater fill angle X12 EPROM circult 256k 512k selection Closed Open a s o X10 Function Enabled PMT RMT functions Creep start Off Off 18 m min 21 ET h e Joy of W e d i n o MSD 1 meter unit layout R3 Set current minimi no function with Kempomig power sources R4 Set current maximum no function with Kempomig power sources R5 Voltage display R6 Current display X3 no function with Kempomig power source X4 no function with Kempomig power sources The Joy of W e d i n o NN Notes
3. Wire feed speed power adjustment Voltage arc length current setting Local remote control Voltage current set value display Dynamis adjustment MIG MAG Synergic program number On off signal lamp Overheat signal lamp Dynamics adjustment MMA Cooling method selection 14 15 16 17 18 19 20 21 22 23 24 25 MSD 1 meter unit Coolant overheat signal lamp Cooling unit test switch Missing pressure signal lamp Main switch 001 Welding current connection Welding current connection Control connection amphenol 10 pin Control connection fuse 6 3 A slow Cooling unit fuse 2 A slow Coolant connector pressure Coolant connector return 20 21 22 23 24 25 The Joy of Welding 4281690A SYNERGIC 1 MIG Prog No Crater fill Burnback H ON 4m NA oug 17 i e x 5 6 7 gt en ee O 2 V H j 3 OFF _1L p Material Wire df 2 3 min max y 1 Synergic program selection 2 Crater fill on off 3 Postcurrent adjustment 40 ms 760 ms Operation principle Kempomig power sources power stage is a traditional half bridge where the DC link s voltage is halved by load capacitors C2 and C3 IGBT transistors work as power switches When both IGBTs are non conductive no power is transferred When the upper IGBT V2 is conductive there is positive voltage in the main transformer s T1 primary and when the lower IGBT V3 is con
4. I d i n o EE eee Solenoid valve control The wf unit develops control voltage for the solenoid valve by pulsing approx 40 V voltage with Pulse ratio of 50 Wire feed motor control Wire feed speed minimum Wire feed speed 10 m min Wire feed speed maximum The wf unit controls the feed motor speed by PWM principle The Joy of Welding Welding gun connection The voltage direction changes every 20 ms in the gun control circuit On the negative half cycle the gun switch and temperature watch PMT W states are read On the positive half cycle the state of an RMT 10 guncontroller is read WIE 3 12 Pistoolilittanta a 10 x tims Trig AT Probe 10 1 5Oms Trig AS HIGH LOW 1 ims Trig AT Probe 10 1 i ms Trig AT Probe 10 1 PMT gun connected PMT gun start 17 ET h e Joy of W e d i n ll M HIGH 600U LOW 0U 10m5 Trig AT Probe 10 1 l ms Trig AT Probe 10 1 PMT connected and RMT in position 1 PMT connected and RMT in position 3 HIGH 10 4U HIGH 0 LOW 0U LOW mes 10m5 Trig AT Probe 10 1 10ms Trig AT Probe 10 1 PMT connected and RMT in position 5 PMT gun start and RMT in position 5 ET h e Joy oF W e I d i n o Signals from Wf unit s connectors Remote controller connector XW101 Ce O a oeno a Ce ow ua ee urona Process selection 6 10V MMA 0 5V or open MIG MAG process Motor gun connection XW101 The Joy of We
5. V28 24 V 5 W on control card A001 If these diodes get damaged there is an insulation problem in the welding gun between welding circuit and start wires Check the intermediate cable between wf unit and power source and see that the process selection works ok I line Check the intermediate cable between wf unit and power source and see that the process selection works ok I line Check the signals on control card AOOI s connector X7 If the signals on control card A001 connector X7 are ok then replace the control card A002 See if there is a resistor R188 mounted onto the control card A001 If one is found remove it Measure the supply voltage Overvoltage watch stops welding if supply voltage rises above 520 Vac Check the rectifier unit VG102 wiring and if the unit is damaged the DC link voltage may momentarily rise above 900 V which activates the watch circuit Check the intermediate cable between power source and wf unit Check the auxiliary transformer and make sure 18 Vac is taken to power source s control card connectors X15 1 and X15 2 Check wf unit control card AOO1 ET h e Joy of W e d i n o NA DISTURBANCE POSSIBLE CAUSE REMEDY The power source can t reach Net fuse has blown maximum output A faulty supply cable A faulty main switch A faulty primary rectifier A faulty control card A001 A faulty control card A001 Wire feed unit error codes Liquid cooled PMT gun has
6. Service manual Ver 1 0 KemepoMic KempoMic 3200 4000W KempoMic KeMmPOMIG 3200W 4000 KEmMPOMIG The Joy of W e d n Qn Contents GOTO EAN E E E E E A E S 3 Technical ata isccascansessadanmreareneeenenceneammaxeanann causes 3 Switches and connectors 0 cece cece ec ecceceecees 4 5 Operation principle cc ceccc cece eee e eee e een 5 IGBT module control 0 0 e cee ee cee eee eee 6 7 Voltage after secondary diodes 0c cc eeeees 8 9 Troubleshooting diagram ccccce eee e cece cues 10 12 Wire feeder s error COdES 00 cece cece eee ee ees 12 Signals between power source and wire feeder 13 15 Solenoid valve control 0 cece cece cece eee eeeeeees 16 Wire feed motor control ccc cece cece eee e ec eees 16 Torch COnnection cc0 cece cece cee ccececuceecuceecuceneas 17 18 Signals from Wf unit s connectors 0 06 19 Cooling unit control 0 0 cece cece ccc eee e ee eens 20 Adjusting the cooling unit pressure watch limit 20 Power source control card A001 layout 21 Wire feed unit control card A001 layout 21 MSD 1 meter unit layout 00 00 coca ees 22 IN OUCS e A S EE E E erase ZO The Joy of W e d i n o LLN General Kempomig power sources a
7. ductive there is negative voltage in the main transformer s T1 primary Power is adjusted by changing the IGBT timings PWM Main transformer T1 secondary voltages are rectified with a full waverectifier Ugo approx 570 V ae y CZ U lt lt lt an e3 ATN C U G2 t ee U 1 a3 Y V PoS B d a O J T l C Uss The Joy of Welding IGBT module control a u Z w L BI o o o im ih i k x ns a tid 4 ail A Gate pulse 10 A 20 4 V MMA B Voltage over the lower IGBT 10 A 20 4 V MMA Inverter frequency approx 17 kHz B7200 U A Gate pulse 100 A 24 0 V MMA B Voltage over the lower IGBT 100 A 24 0 V MMA Inverter frequency approx 17 kHz B7200 Y The Joy of Welding IGBT module control Ww Lap 23 LS GIA 22 45 GAC 21 15 GAC 5 3 GIPL g G2PL GEM G 1 5 A Gate pulse 320 A 32 8 V MMA B Voltage over the lower IGBT 320 A 32 8 V MMA Inverter frequency approx 17 kHz A Gate pulse 400 A 36 0 V MMA B Voltage over the lower IGBT 400 A 36 0 V MMA Inverter frequency approx 17 kHz The Joy of Welding Voltage after secondary diodes HAS YO201 2268 2161 C Voltage after the secondary diodes 10 A 20 4 V MMA Frequency approx 35 kHz Probe 10 1 fps Trig BI C Voltage after the secondary diodes 100 A 24 0 V MMA F
8. he intermediate cable between power source and wf unit Check the primary rectifier and IGBT module condition Check the load capacitors See 1f there are marks of insulation damages on the main circuit card Check the aux transformer Check the secondary diodes Check flat cables amp connectors between control card A001 and operating panel Replace the operating panel Check flat cables amp connectors between control card A001 and operating panel Disconnect the flat cable from P002 synergy card As a result of this if the power source goes to MIG then replace the P002 T he Joy of W e d n Qn DISTURBANCE POSSIBLE CAUSE Error code E08 is shown on the panel display The equipment welds ok on spray arc values but on short and globular arc it is impossible to weld The power source doesn t start the cooling unit The equipment welds poorly on short and globular arc The arc 1s intermitted and overheat signal lamp is flashing at the same time Wf unit doesn t control the power source Faulty welding gun Faulty wf unit control card AOO1 Faulty intermediate cable Faulty intermediate cable Faulty power source control card A001 Faulty power source control A002 Power source s control card A001 DC link overvoltage Faulty intermediate cable Faulty aux transformer Faulty control card A001 REMEDY Check the welding gun condition Check the wf unit s zener diodes V27 and
9. lding Cooling unit control The cooling unit is controlled on only on MIG process while start is active Cooling unit stops the power stage if a missing coolnat pressure is detected or the coolant has overheated Connector X7 1 Cooling unit start in start the power source control card A001 pulls down the voltage on connector X 7 1 X7 2 Supply voltage to control card A002 electronics 24 V XIN GND X7 4 Stop if coolant pressure is less than 1 bar or the coolant temperature rises above 60 C then the control card A002 pulls down the voltage on connector X7 4 which shuts the power source down un LJ ns LJ START Adjusting the cooling unit pressure watch limit Kempomig 3200W 4000W If the missing coolant pressure signal lamp 17 is lit though coolant circulates normally then The pressure watch limit can be adjusted as follows 1 Run the pump by the test switch 2 Adjust the pressure switch adj Screw counter clockwise until the warning lamp goes out 3 Check the operation with a test weld 20 KEMPPI The Joy of Welding Power source control card A001 layout B S ee R39 Current max R75 Inv frequency R120 Voltage max R150 Voltage min R152 Current min R160 MMA ignition pulse X16 Supply voltage selection 460 V X17 Supply voltage selection 400 V X18 MMA characteristic curve for testing without a wire feeder unit R50 Post gas time 0 2 s A3 0
10. overheated Check the net fuses Check the supply cable Check the main switch Check the primary rectifier Measure the DC link voltage during idling and under load 530 570 Vdc On the power source s control card A001 check that the IGBT module s gate pulses are correct Replace the control card if necessary On the power source s control card A001 check that the set value is developed correctly H line 0 10 Vdc Replace if necessary Gun switch is being pressed while MMA welding has been selected by the FEED panel Wf motor has been overloaded me PMT gun has been tried to use though PMT RMT functions have been disabled by jumper 5 Shielding gas watch has interrupted welding GG 400 Sethe Joy of W e d n Qn Signals between power source and wire feeder unit Signals in the control cable between the power source and the wire feeder unit Pin Signal Explanation B oo oaae Supply voltage for wire feeder unit fuse 6 3 A slow Supply voltage for wire feeder unit fuse 6 3 A slow E Powersowcesize Are Power source size detection Arc on info to the wf unit on oR w ae 0 10V Set value information to the power source current or voltage Process selection 10 V MMA eee anaes 0 5 3 5 V MIG MAG process and MIG MAG dynamics setting Voltages in the E line of control cable between the power source and the wire feeder HIGH 3 60U LOW gt Power source size Arc on info
11. re MIG MAG and MMA power sources designed for professional use Kempomig power sources are inverter power sources based on IGBTs controlled by PWM principle The operating frequency is fixed on 18 kHz throughout the machine s operating range Kempomig power source together with Feed unit form a compilation in which the Feed unit controls all the operations Feed unit s all functions are programmatically controlled Technical data 3200 4000 Supply voltage 3 50 60Hz 400 V 10 15 3 50 60Hz 400 V 10 15 13 4 KVA 320 A 50 ED 18 4 kVA 400A 40 ED Supply cable fuses 4x 2 58 16A slow 4x 2 5S 16A slow Loadability 320 A 32 8 V 50 ED 400 A 36 0 V 40 ED 250 A 30 0 V 100 ED 250 A 30 0 V 100 ED Welding current adj range 10 A 320A MMA 10 A 400 A MMA Welding voltage adj range 10 V 35 V MIG 10 V 40 V MIG Max welding voltage 40 V 320 A MMA 40 V 400 A MMA approx 75V approx 75 V ing power lt 55 Degree of protection IP 23C IP 23C Measures 3200W 4000W Watertank voume ST Cooling power ew Max flow Alin FEED 400 Supply voltage 30 Vac 50 60 Hz 150 VA Loadability 60 ED 400 A 100 ED 310A Wf speed 0 5 18 25 m min Wire spool max 20 kg gt 300 mm 15 kg Measures The Joy of Welding Switches and connectors CON OO OI RP WN KEMPOMIG Process selection Local remote control selection Wire feed speed plate thickness display
12. requency approx 35 kHz Probe 10 1 cips Trig BI The Joy of Welding Voltage after secondary diodes YO201 2268 2161 EOR EET C Voltage after secondary diodes 320 A 32 8 V MMA Frequency approx 35 kHz Probe 10 1 dus Trig BI na ol bs C Voltage after secondary diodes 400 A 36 0 V MMA Frequency approx 35 kHz Probe 10 1 dlus Trig BI The Joy of W e d n Qn Troubleshooting The device may be repaired only by a person legally authorized perform electric work Always check the device visually first to find possible damages like loose wires breaks or signs of overheating Also note the condition of the welding cables welding gun and wire feed mechanism Troubleshooting diagram DISTURBANCE The machine won t start WF unit s displays remain blank The fuses blow during machine startup The machine welds but displays remain blank Power source stays on MMA even though MIG is selected by the panel POSSIBLE CAUSE Net fuse has blown Faulty supply cable Faulty main switch Faulty aux transformer Faulty intermediate cable A faulty primary side power semiconductor A faulty main circuit card A faulty aux transformer A faulty secondary unit Faulty flat cable Faulty operating panel Faulty flat cables Faulty synergy card P002 REMEDY Check the net fuses Check the supply cable Check the main switch Check the aux transformer Check t
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