Kemppi Kempact RA 181A, 251R, 251A, 253R, 253A, 323R, 323A welding machine Service manual
Below you will find brief information for Kempact RA 181A, Kempact RA 251R, Kempact RA 251A, Kempact RA 253R, Kempact RA 253A. Kempact RA welding machines are a compact MIG/MAG welding machines designed for professional use. The power source part of the machine is based on inverter technology. IGBTs are used as power switches in the inverter. Kempact RA welding machines also contain all circuitry that is needed to drive wire feeder part of the machine and also easy to use intuitive user interface. Most of the welding machine functions are controlled using a microcontroller.
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SERVICE MANUAL KEMPACT RA 181A 251R/251A 253R/253A 323R/323A Kemppi Oy SERVICE MANUAL 1 (32) KEMPACT RA CONTENTS 1. PARTS OF MACHINE................................................................................................................................................................................ 3 2. TECHNICAL INFORMATION ..................................................................................................................................................................... 6 2.1. Technical data ................................................................................................................................................................................ 6 2.2. Main circuit diagrams ..................................................................................................................................................................... 8 3. DESCRIPTION OF OPERATIONS ............................................................................................................................................................. 10 3.1. Main components ........................................................................................................................................................................ 11 3.1.1. Terminal block X001............................................................................................................................................................. 11 3.1.2. Varistors R001 ...................................................................................................................................................................... 11 3.1.3. Main switch S001 ................................................................................................................................................................. 11 3.1.4. Terminal block X009............................................................................................................................................................. 11 3.1.6. Test connector X006 ............................................................................................................................................................ 11 3.1.7. Auxliary transformer T002 and rectifier bridge G003 .......................................................................................................... 11 3.1.8. Control card A001 ................................................................................................................................................................ 11 3.1.8.1. Auxiliary power supply ................................................................................................................................................ 11 3.1.8.2. Microcontroller ............................................................................................................................................................ 11 3.1.8.3. Motor control .............................................................................................................................................................. 11 3.1.8.4. PWM ............................................................................................................................................................................ 12 3.1.9. Fans M001, M002 ................................................................................................................................................................ 12 3.1.10. Solenoid valve Y001 ........................................................................................................................................................... 12 3.1.11. Wire feed motor M003 ...................................................................................................................................................... 12 3.1.12. Brights led card P002 ......................................................................................................................................................... 12 3.1.13. Panel card P001 ................................................................................................................................................................. 12 3.1.14. Main transformer T001 ...................................................................................................................................................... 12 3.1.15. Secondary rectifier card Z002 ............................................................................................................................................ 12 3.1.16. Secondary choke L001 ....................................................................................................................................................... 12 3.1.17. Output RFI filter C001, C002 .............................................................................................................................................. 13 3.1.18. Output terminal X004 ........................................................................................................................................................ 13 3.1.19. Euro connector X005.......................................................................................................................................................... 13 3.2. Main circuit diagram 181-, 251-models ....................................................................................................................................... 13 3.2.1. PFC Choke L001 .................................................................................................................................................................... 13 3.2.2. PFC circuit auxiliary transformer T003 ................................................................................................................................. 13 3.2.3. Main circuit card Z001 ......................................................................................................................................................... 13 3.2.3.1. EMC Filter .................................................................................................................................................................... 13 3.2.3.2. Inrush current limiting ................................................................................................................................................. 13 3.2.3.3. IGBT driver ................................................................................................................................................................... 13 3.2.3.4. Current transformer T1 ............................................................................................................................................... 13 3.2.3.5. Main circuit .................................................................................................................................................................. 13 3.2.3.6. PFC Boost control circuitry .......................................................................................................................................... 13 3.3. Main circuit diagram 253-, 323-models ....................................................................................................................................... 14 3.3.1. Main circuit card Z001 ......................................................................................................................................................... 14 3.3.1.1. EMC filter ..................................................................................................................................................................... 14 3.3.1.2. Inrush current limiting ................................................................................................................................................. 14 3.3.1.3. IGBT driver ................................................................................................................................................................... 14 3.3.1.4. Current transformer T1 ............................................................................................................................................... 14 3.3.1.5. Main circuit .................................................................................................................................................................. 14 4. MAIN CIRCUIT CARD Z001 .................................................................................................................................................................... 15 4.1. Kempact 181, 251 ........................................................................................................................................................................ 15 4.1.1. Connectors ........................................................................................................................................................................... 15 4.2. Kempact 253, 323 ........................................................................................................................................................................ 17 4.2.1. Connectors ........................................................................................................................................................................... 17 5. SECONDARY RECTIFIER CARD Z002 ...................................................................................................................................................... 19 5.1. Connectors ................................................................................................................................................................................... 19 Kemppi Oy SERVICE MANUAL 2 (32) KEMPACT RA 6. CONTROL CARD A001 ........................................................................................................................................................................... 20 6.1. Leds .............................................................................................................................................................................................. 20 6.2. Connectors ................................................................................................................................................................................... 20 7. PANEL CARD P001 ................................................................................................................................................................................ 22 7.1. Connectors ................................................................................................................................................................................... 22 8. OPERATIONAL MEASURINGS AND TESTS ............................................................................................................................................. 23 8.1. Kempact 181, 251 ........................................................................................................................................................................ 23 8.1.1 Primary rectifier V24, 25 ....................................................................................................................................................... 23 8.1.2. IGBT module V1 ................................................................................................................................................................... 24 8.2. Kempact 253, 323 ........................................................................................................................................................................ 25 8.2.1. Primary rectifier, V1 ............................................................................................................................................................. 25 8.2.2. IGBT module, V2 ................................................................................................................................................................. 26 8.3. Secondary rectifier card, Z002 ..................................................................................................................................................... 27 8.4. PTC’s, overheat protection ........................................................................................................................................................... 28 8.5. Control card A001 ........................................................................................................................................................................ 28 9. MAIN COMPONENTS INSTALLATION .................................................................................................................................................... 28 9.1. Main circuit card Z001 .................................................................................................................................................................. 28 9.2. Secondary rectifier card Z002 ...................................................................................................................................................... 29 9.3. Other components ....................................................................................................................................................................... 29 10. ERROR CODES ..................................................................................................................................................................................... 30 General Kempact RA(Regular / Adaptive ) welding machines are compact MIG/MAG welding machines designed for professional use. The power source part of the machine is based on inverter technology. IGBTs are used as power switches in the inverter. Kempact RA welding machines also contain all circuitry that is needed to drive wire feeder part of the machine and also easy to use intuitive user interface. Most of the welding machine functions are controlled using a microcontroller. Before removing any covers or commencing any testing or measurement disconnect the power source from the mains voltage. Dangerous DC voltage may still exist after the removal of the input voltage. Machine discharges the voltage while it is turned off, but it is always better to ensure this by measuring the voltage. Digital multimeters may give different values depending the specifications they have. For example diode measuring values may vary between the multimeters models. Special attention must be considered while working with the internal parts. The device may be repaired only by a person legally authorized to perform electrical work. Kemppi Oy SERVICE MANUAL KEMPACT RA 1. PARTS OF MACHINE Kempact RA (253, 323) Kemppi Oy 3 (32) SERVICE MANUAL 4 (32) KEMPACT RA Kempact RA (253, 323) ITEM CODE W005603 W005926 W005791 W006602 9568913 W004288 9771530 W005782 9792639 W005779 W006130 W006128 Kemppi Oy PART 1 2 3 5 6 7 8 9 10 11 12 ITEM DESCRIPTION FRAME WA KEMPACT RA KEMPACT RA 3PH WF ASSEMBLY DT400 RI KEMPACT WF MOUNTING FRAME INSULATOR SOLENOID VALVE Kempact RA HOSE CONNECTOR R1/8-6ML INSULATION BUSHING WELD CONNECTOR DIX 50 FEMALE TERMINAL BLOCK INSULATING PLATE 3PH CABLE CLAMP TERMINAL BLOCK COVER KEMPACT RA ANGLE SUPPORT RIGTH KEMPACT RA ANGLE SUPPORT LEFT KEMPACT RA PCS 1 1 1 1 1 5 1 1 1 1 1 1 QTY 1 1 1 1 1 1 1 1 1 1 1 1 SERVICE MANUAL 5 (32) KEMPACT RA W006215 W006154 W006153 W006429 W003701 3133500 4265820 4270940 4267970 2062070 W005661 W006115 W005790 W005041 W002918 W005793 W005872 W005821 W005813 W006249 W006176 W006208 W005918 W006392 W006180 9449407 9441047 9547150 9476520 9420120 W001624 9449461 9449233 9433024 9433007 9433043 9433027 9410250 9432824 9410108 W006603 9425216 9592164 W006222 4292020 6184211T 4262810 W006201 W006234 W005681 4252013 9840486 13 16 18 19 20 54 23 24 26 26 27 28 29 30 32 33 34 36 37 38 40 41 43 47 39 44 45 48 50 52 55 56 57 58 59 60 61 67 COMPONENT FRAME ASSEMBLY KEMPACT RA POLARITY CABLE TO DIX KEMPACT RA POLARITY CABLE TO ADAPTER KEMPACT POLARITY PROTECTION 25 MM2 MINUS POLARITY PROTECTION 25 MM2 PLUS LATCH FOR SPOOL HUB SPECIAL NUT M16X1 PRESSURE SPRING HUB BRAKE PAD WIRE SPOOL HUB PARTITION WIND PLATE KEMPACT RA AIR GUIDE PLATE KEMPACT LOWER COVER KEMPACT RA SPOOL CASING COVER KEMPACT RA FAN LOWER GRILL KEMPACT RA HINGE KEMPACT RA LATHC LOCK KEMPACT RA LATCH KEMPACT RA DOOR WITH MARKING KEMPACT RA PANEL BASE ASSY 3PH KEMPACT RA PANEL FRAME ASSEMBLY KEMPACT R PANEL COVER KEMPACT RA PANEL COVER SPRING KEMPACT RA HINGE PIN KEMPACT RA PT-SCREW 4X16 WN1452 TX20 ZN BLPAS ZN MPASSOCKET HEAD CAP SCREW M5X16 BN1206 CASTOR 250/50-20/60 MM CIRCLIP 15X1.5 DIN 6799 WASHER M20 DIN 125 A ZN SQUARE NUT M5 DIN 557 PT-SCREW 5X14 WN1452 TX20 ZN BLPAS ZN MU SELF-TAPPING SCREW TX25 M5X16 DIN7500CE Z1N BLAC1K TORX SCREW M4X10 DIN7985 T20 ZN BLACK TORX SCREW M3X20 DIN7985 T15 ZN BLACK TORX-SCREW M5X8 DIN7985 T25 ZN BLACK TORX SCREW M4X20 DIN7985 T20 ZN BLACK FLANGE NUT DIN6923 M6 14583 TX DIN6900-3 HEX NUTM8 DIN 934-8 ZN FILTER MOUTH COVER KEMPACT RA INTERNAL TAB WASHER D16 DIN 462 ZN BOTTLE FASTENING BAND KEMPACT RA CODING WIRE KEMPACT RA HOSE GROUNG CABLE 25-5 FLAT CABLE L = 175 KEMPACT 253R PRODUCT LABEL RATING PLATE KEMPACT 253 R MAIN CIRCUIT DIAGRAM KEMPACT RA 253 323 CONNECTOR 4 X 1.5MM2-5M FOAMED PLASTIC SHEET 2MM NOTE ! More info available from: [email protected] (email). Kemppi Oy 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 2 1 1 1 1 1 1 2 2 4 4 2 2 4 2 8 7 2 2 2 2 6 8 2 1 1 2 1 1 1 1 1 0 0 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 0.5 M2 SERVICE MANUAL 6 (32) KEMPACT RA 2. TECHNICAL INFORMATION 2.1. Technical data Kempact 181A Kempact 251R, 251A Connection voltage 50/60Hz 230V+- 15% 1~ 50/60Hz 240V+- 15% 1~ Rated power at max. current 50% ED I1max (180A) 5.16VkA/5.1kW 30% ED I1max (250A) 8.5kVA/8.4kW Supply current 50% ED I1max (180A) 22A 30% ED I1max (250A) 36A 100% EDI1eff (140A) 16A 3G1.5 (1.5mm2, 5m) 100% EDI1eff (150A) 17A 3G2.5 (2.5mm2, 5m) Type C Welding range 16A 10V/20A 26V/180A No load voltage 36V Connection cable H07RN-F Fuse Type C Idle power H07RN-F 20A 10V/20A 29V/250A 36V 35W 35W Power factor at max. 180A/25,75V 0.99 250A/26.5V 0.99 Efficiency at 100% ED Wire feed speed adjustment range 140A/21V 0.82 150A/21.5V 0.82 Voltage adjustment range Filler wires wire spool Weight 1.0-18.0m/min 8.0-26.0V 8.0-29.0V Fe solid 0.8…1.2 mm 0.8…1.2 mm Fe cored wires 0.8…1.2 mm 0.8…1.2 mm Ss 0.8…1.2 mm 0.8…1.2 mm Al 1.0…1.2 mm 1.0…1.2 mm CuSi 0.8…1.0 mm 0.8…1.0 mm max 300 mm/ 20 kg CO2, Ar, Ar+CO2 mixed 300 mm/ 20 kg CO2, Ar, Ar+CO2 mixed LxWxH Not including gun and gables 623x579x1070 mm Shielding gases External dimensions 1.0-14.0m/min 44 kg LxWxH Not including gun and gables 623x579x1070 mm 44 kg Temperature class F(155 C) F(155 C) EMC class A A Degree of protection IP23S IP23S Operating temperature range -20…+40 °C -20…+40 °C Storage temperature range -40…+60 °C -40…+60 °C Standards IEC 60974-1 IEC 60974-1 IEC 60974-5 IEC 60974-5 IEC 60974-10 IEC 60974-10 IEC 61000-3-12 IEC 61000-3-12 Kemppi Oy SERVICE MANUAL 7 (32) KEMPACT RA Kempact 253R, 253A Kempact 323R, 323A Connection voltage 50/60Hz 400V+- 15% 3~ 50/60Hz 400V +- 15% 3~ Rated power at max. current 40% ED I1max (250A) 8.34kVA/7.73kW 35% ED I1max (320A) 12kVA/11.3kW Supply current 40% ED I1max (250A) 11.9A 35% ED I1max (320A) 17.2A 100% EDI1eff (150A) 6.1A 4G1.5 (1.5mm2, 5m) 100% EDI1eff (190A) 8.2A 4G1.5 (1.5mm2, 5m) Type C Welding range 10A 10V/20A 31V/250A No load voltage 41V Connection cable H07RN-F Fuse Type C Idle power H07RN-F 10A 10V/20A 32.5V/320A 45V 25W 25W Power factor at max. 250A/26.5V 0.93 320A/30V 0.94 Efficiency at 100% ED Wire feed speed adjustment range 150A/21.5V 0.88 190A/23.5V 0.86 1.0-18.0m/min 1.0-20.0m/min 8.0-31.0V 8.0-32.5V Fe solid 0.8…1.2 mm 0.8…1.2 mm Fe cored wires 0.8…1.2 mm 0.8…1.2 mm Ss 0.8…1.2 mm 0.8…1.2 mm Al 1.0…1.2 mm 1.0…1.2 mm CuSi 0.8…1.0 mm 0.8…1.0 mm max 300 mm/ 20 kg CO2, Ar, Ar+CO2 mixed 300 mm/ 20 kg CO2, Ar, Ar+CO2 mixed LxWxH Not including gun and gables 623x579x1070 mm Voltage adjustment range Filler wires wire spool Shielding gases External dimensions Weight 44 kg LxWxH Not including gun and gables 623x579x1070 mm 44 kg Temperature class F(155 C) F(155 C) EMC class A A Degree of protection IP23S IP23S Operating temperature range -20…+40 °C -20…+40 °C Storage temperature range -40…+60 °C -40…+60 °C Standards IEC 60974-1 IEC 60974-1 IEC 60974-5 IEC 60974-5 IEC 60974-10 IEC 60974-10 IEC 61000-3-12 IEC 61000-3-12 Kemppi Oy SERVICE MANUAL KEMPACT RA 2.2. Main circuit diagrams Kemppi Oy 8 (32) SERVICE MANUAL KEMPACT RA Kemppi Oy 9 (32) SERVICE MANUAL 10 (32) KEMPACT RA 3. DESCRIPTION OF OPERATIONS Kempact RA welding machine consists of several circuit cards and separate components. In the following sections are described the main components and separate cards functions. Machine basic function (machine start up), after mains voltage is switched on: 1. DC-link capacitors are charged and if there is no over voltage condition inrush relay is switched on after a short delay 2. If there is PFC circuit it’s enabled after a short delay 3. Fans are started for a test run after a short delay 4. Welding is enabled Kempact RA machines have following parts and components: • • • • • • • • • • • • • • • • • • • • • Terminal block X001 Varistors R001 Main switch S001 Terminal block X009 Main circuit card Z001 o EMC filter o Inrush current limiting o IGBT driver o Current transformer T1 o Main circuit PFC choke (181-, 251-models) PFC circuit auxiliary transformer T003 (181-, 251-models) Test connector X006 Auxiliary transformer T002 Rectifier bridge G003 Control card A001 Cooling fans M001 and M002 Gas valve Y001 Wire feed motor M003 Brights led card P002 Panel card P001 Main circuit card Z001 Secondary rectifier card Z002 Secondary choke L001 Output RFI filters C001 and C002 Euro connector X005 Kemppi Oy SERVICE MANUAL 11 (32) KEMPACT RA 3.1. Main components 3.1.1. Terminal block X001 • Mains cable is connected to the terminal block X001. The terminal block is located in the mains cable connection box on the back plate of the machine. Also varistors R001 are connected to this terminal block. From the terminal block mains voltage is wired to main switch S001 3.1.2. Varistors R001 • • The varistors are located in the mains cable connection box on the backside of the welding machine The purpose of the varistors is to protect the welding machine against voltage spikes coming from the mains 3.1.3. Main switch S001 • The main switch is located in the upper part of the machine close to the user interface 3.1.4. Terminal block X009 • • From the main switch S001 mains voltage is wired to terminal block X009 which is located on the front side of the component frame. From this terminal block mains voltage is wired to the main circuit card Z001 PE (protective earth) is wired from this terminal block into the component frame and connected to a chassis ground terminal 3.1.6. Test connector X006 • Possible to measure DC-link voltage during service 3.1.7. Auxliary transformer T002 and rectifier bridge G003 • • • • • Auxliary transformer is a 60VA toroidal transformer It has 230V and 400V inputs and 18V output 230V input is used in 181 and 251 machines 400V input is used in 253 and 323 machines Auxliary transformer output voltage is rectified using rectifier bridge G003. Both the auxiliary transformer and the rectifier bridge are located inside the component frame 3.1.8. Control card A001 3.1.8.1. Auxiliary power supply • • • Auxliary voltage +24V is used by fans, gas valve, inrush relay and brights LED. This voltage is also used to drive optocoupler that enables PFC and panel backlight. To generate +24V voltage auxliary transformer T002 output is full wave rectified using rectifier bridge G003 Auxliary voltage +15V is used by IGBT driver (V20, V22, V23, V25 etc.), PWM IC (N5), motor control half bridge driver (N2) and other circuits Auxliary voltage +5V is used by microcontroller N7, panel card P001 and other circuits 3.1.8.2. Microcontroller • • Many of the control card A001 functions are using the microcontroller N7. Basic functions of the microcontroller include controlling output voltage of the inverter. The microcontroller measures output voltage and changes peak current reference of the inverter to regulate it The microcontroller also regulates wire feed speed by setting motor current reference and measuring EMF of the motor 3.1.8.3. Motor control • • • Wire feed motor control is based on EMF (electro magnetic force) measurement principle Wire feed mechanism doesn’t have tachometer, instead motor current is driven to zero every ca. 10ms and the EMF of the motor is measured before motor current is increased again. This EMF information is then used to regulate motor speed The microcontroller measures motor EMF and controls motor current to regulate motor speed Kemppi Oy SERVICE MANUAL 12 (32) KEMPACT RA 3.1.8.4. PWM • • PWM (pulse width modulation) circuit is for controlling the inverter Peak current-mode control is used to directly control primary current which is measured by current transformer T1 l 3.1.9. Fans M001, M002 • • • Machine fans are controlled by the control card A001 microcontroller. If there are two fans (3~models) in the machine they are started in sequence so that second fan is started after 3s delay. When welding starts fans are started and when welding stops fans are stopped after post run time In error situation fans are always on Fans are stopped if arc is not established during first 5s after start 3.1.10. Solenoid valve Y001 • Solenoid valve is controlled by control card A001 auxiliary voltage + 24 V 3.1.11. Wire feed motor M003 • • Wire feed motor control is based on EMF (electro magnetic force) measurement principle. Wire feed mechanism doesn’t have tachometer, instead motor current is driven to zero every ca. 10ms and the EMF of the motor is measured before motor current is increased again. This EMF information is then used to regulate motor speed. Wire feed motor speed control is done using the microcontroller. The microcontroller measures motor EMF and controls motor current to regulate motor speed There is no special wire inch button. Wire inch is started like normal welding using the gun. When the user pushes start button wire feed motor and the power source start. Wire feed speed is creep start speed which is slower than normal wire feed speed. If arc is not established during first 5s the power source is shut down but wire feeding continues with creep start speed for 30s. When the inverter is ON operating voltage for the wire feed motor is taken from the output of the power source. When the inverter is SHUT DOWN after 5s operating voltage for the wire feed motor is taken from the auxliary transformer for safety reasons. Because of this current limit of the wire feed motor has to be lowered. For this reason also torque of the wire feed motor is reduced after 5s 3.1.12. Brights led card P002 • Controlled by control card A001 auxiliary voltage + 24 V 3.1.13. Panel card P001 • There is two panel versions R and A (R-version has limited functions). Panel is connected to the control card A001 with 16-wire ribbon cable o When machine start up panel is showing power source size and SW version 3.1.14. Main transformer T001 • • • In the 181 and 251 machines the main transformer has 19 turn primary winding and center tapped secondary 2 + 2 turns (turns ratio 9.5:1) In the 253 machine the main transformer has 27 turn primary winding and center tapped secondary 2 + 2 turns (turns ratio 13.5:1) In the 323 machine the main transformer has 25 turn primary winding and center tapped secondary 2 + 2 turns (turns ratio 12.5:1) 3.1.15. Secondary rectifier card Z002 • • • • Z002 is used to rectify the secondary current. There are 4 60A diodes connected in parallel in both legs of the rectifier (V1 – V8) in 323 power source. 250 amps machine has 3+3 diodes Capacitors C1 and C2 and resistors R3 and R4 form a snubber circuit. The snubber circuit reduces the voltage stress of the diodes caused by the reverse recovery current snap off Varistors R1 and R2 are for TIG ignition spark protection Operating voltage for the wire feed motor is rectified to capacitors C3-C5 3.1.16. Secondary choke L001 • The secondary choke L001 reduces ripple content of the secondary current Kemppi Oy SERVICE MANUAL 13 (32) KEMPACT RA 3.1.17. Output RFI filter C001, C002 • Capacitors C001 and C002 connected to the dowel screws (+ and -) reduce radio frequency interference 3.1.18. Output terminal X004 • Dix connector X004 3.1.19. Euro connector X005 3.2. Main circuit diagram 181-, 251-models • 181 and 251 machines have many common technical details with 253 and 323 machines. They have e.g. the same P001, P002 and Z002 cards. Main differences to 253 and 323 machines are described here 3.2.1. PFC Choke L002 181 and 2511 machines include PFC (Power Factor Correction) circuit. This is implemented using boost topology. The Boost topology has choke in the input side of the converter. In Kempact 181 and 251 this choke is located on the front side of the component frame from where it is wired into the component frame 3.2.2. PFC circuit auxiliary transformer T003 PFC circuit auxiliary power is generated using small toroidal transformer located inside the component frame 3.2.3. Main circuit card Z001 3.2.3.1. EMC Filter • Capacitors C7, C10, C15, C16 and inductor T6 form an EMC filter. The purpose C17 and R18 is to dampen common mode transients coming from mains 3.2.3.2. Inrush current limiting • PTC resistors R16 and R17 limit inrush current when the power source is switched on. PTCs are bypassed with relays K1 and K2 after DC link capacitors have been charged. Relays K1 and K2 are controlled by the microcontroller 3.2.3.3. IGBT driver • IGBT driver consists of gate transformers T2 and T3 and surrounding components 3.2.3.4. Current transformer T1 • Current transformer T1 is monitoring primary current and stops power stage operation if current is raising too high 3.2.3.5. Main circuit • • • • The main circuit consists of boost type PFC circuit followed by H-bridge type converter. Both parts of the main circuit are implemented using the same 600V, 75A six pack IGBT module One leg of the IGBT module is used for the Boost PFC circuit. Lower IGBT is used as the Boost power switch and the anti-parallel diode of the upper IGBT as the boost diode The switching frequency of the boost circuit is ca. 15 kHz. The boost circuit raises DC link voltage to ca. 370V. Boost input current is measured using shunt resistors R58, R59, R65, R66. H – bridge is implemented using the other two legs of the IGBT module 3.2.3.6. PFC Boost control circuitry • PFC control circuitry is located on the primary side. Auxliary transformer T003 supplies operating voltage for the PFC control circuitry. The output voltage of the T003 is first rectified and then linear regulator is used to regulate auxiliary voltage to 15V. PFC control IC N1 regulates DC-link voltage to approximately 370V Kemppi Oy SERVICE MANUAL 14 (32) KEMPACT RA 3.3. Main circuit diagram 253-, 323-models 3.3.1. Main circuit card Z001 3.3.1.1. EMC filter • • • Capacitors C5 - C7, C8 - C10, C19 - C21 and inductors T4 and L1 form an EMC filter First part of the filter is three phase filter which is located before the three phase rectifier V2 Second part is DC filter (L1) which is located after three phase rectifier 3.3.1.2. Inrush current limiting • • • PTC resistor R1 limits inrush current when the power source is switched on R1 is bypassed with relays K1 and K2 after DC link capacitors C17, C18 have been charged Relays K1 and K2 are controlled with the microcontroller 3.3.1.3. IGBT driver • IGBT driver consists of gate transformers T2 and T3 and surrounding components 3.3.1.4. Current transformer T1 • Current transformer T1 is monitoring primary current and stops power stage operation if current is raising too high 3.3.1.5. Main circuit • • • Main circuit topology is H-bridge. The H-bridge topology requires four power switches which are implemented using IGBT module V2. The switching frequency of the H – bridge is 20 kHz 253 power source uses 50A module 323 power source uses 75A module UG1 Approx.. + 570 V G1 UG1 UG2 G2 G5 UG2 UG3 L1 UT1 UG5 G3 UG3 G4 UL1 UG4 UT1 UG4 UG5 UL1 When IGBT-transistors G1 and G4 conduct, there is a positive voltage U in main transformer T1 primary and when IGBTT1 transistors G2 and G3 conduct there is a negative voltage U in main transformer primary. Power is adjusted by changing the T1 IGBT timings (PWM). Kemppi Oy SERVICE MANUAL KEMPACT RA 4. MAIN CIRCUIT CARD Z001 4.1. Kempact 181, 251 4.1.1. Connectors Pin X1 X2 Signal Mains voltage Mains voltage Pin X4 Signal Chassis ground connector Pin X5 X6 Signal Auxiliary transformer connection, auxliary transformer is protected with PTC resistors R63 and R64 PFC Auxiliary transformer connection, auxliary transformer is protected with PTC resistors R63 and R64 Kemppi Oy Description Main voltage connector Mains voltage connector 15 (32) SERVICE MANUAL KEMPACT RA Pin X7 X8 X17 X19 Signal Main transformer connections Main transformer connections Main transformer connections Main transformer connections Pin X9 Signal PFC auxiliary voltage connector Pin X10:1 X10:2 X10:3 X10:4 X10:5 X10:6 X10:7 X10:8 X10:9 X10:10 X10:11 X10:12 Signal Inrush Relay OV Opto P Primary current transformer Inrush Relay OV Opto N Primary current transformer IGBT Drive B PFC ON/OFF P IGBT Drive A PFC ON/OFF N - Pin X11 X12 X14 X15 Signal PFC choke connections PFC choke connections PFC choke connections PFC choke connections Pin X13 X16 Signal DC-link voltage DC-link voltage Kemppi Oy Description Other end of the inrush relay coil Over voltage optocoupler other end Primary current transformer other end Other end of the inrush relay coil Over voltage optocoupler other end Primary current transformer other end Other end of the IGBT driver transformer primary PFC on/off opto coupler diode positive end Other end of the IGBT driver transformer primary PFC on/off opto coupler diode negative end - 16 (32) SERVICE MANUAL KEMPACT RA 4.2. Kempact 253, 323 4.2.1. Connectors Pin X1 X2 X3 Signal Mains voltage Mains voltage Mains voltage Pin X4 Signal Chassis ground connection Pin X5 Signal Auxiliary transformer connection, auxliary transformer is protected with PTC resistors R16 and R17 Pin X7 X8 Signal Main transformer connections (253 machine use two flat connectors, 323 use four) Main transformer connections (253 machine use two flat connectors, 323 use four) Kemppi Oy Description Main voltage connector Mains voltage connector Mains voltage connector 17 (32) SERVICE MANUAL KEMPACT RA X13 X14 Main transformer connections (253 machine use two flat connectors, 323 use four) Main transformer connections (253 machine use two flat connectors, 323 use four) Pin X9:1 X9:2 X9:3 X9:4 X9:5 X9:6 Signal IGBT Drive B OV Opto P Inrush Relay IGBT Drive A OV Opto N Inrush Relay Pin X10 Signal Primary current transformer connector Pin X11 X12 Signal DC-link voltage DC-link voltage Kemppi Oy Description Other end of the IGBT driver transformer primary Over voltage optocoupler other end Other end of the inrush relay coil Other end of the IGBT driver transformer primary Over voltage optocoupler other end Other end of the inrush relay coil 18 (32) SERVICE MANUAL KEMPACT RA 5. SECONDARY RECTIFIER CARD Z002 5.1. Connectors Pin X1 X2 X3 X4 X5 X6 Signal Main transformer secondary Main transformer secondary Z002 card connection to secondary profile Z002 card connection to secondary profile Rectified +24V Polarity connector (-) Kemppi Oy 19 (32) SERVICE MANUAL KEMPACT RA 6. CONTROL CARD A001 6.1. Leds Led H1 H2 H4 H5 H6 Description Auxiliary voltage + 15V Status of IGBT driver, when this LED is lit IGBT driver is active RDI debug purposes Motor control input voltage +24V voltage 6.2. Connectors Pin X2:1 X2:2 X2:3 X2:4 X2:5 X2:6 Signal + 50 V GND + 24 V Motor (+) Motor (-) GND Kemppi Oy Description Secondary voltage from secondary card Ground +24V from the auxiliary transformer Wire feed motor (+) Wire feed motor (-) Ground 20 (32) SERVICE MANUAL KEMPACT RA Pin X3:1 X3:2 X3:3 X3:4 X3:5 X3:6 X3:7 X3:8 X3:9 X3:10 X3:11 X3:12 Signal Vout CT (B) CT (A) GND GND J3 GND GND GND J2 J1 J0 Description Output voltage measurement from the dowel screw (+) Current transformer secondary (B). Current transformer secondary (A) Ground Ground Primary current limit jumper. Ground Ground Ground Machine type jumper J2 Machine type jumper J1 Machine type jumper J0 Pin X4:1 X4:2 X4:3 X4:4 X4:5 X4:6 X4:7 X4:8 X4:9 X4:10 X4:11 X4:12 Signal Fan1 (-) Fan2 (-) Gas Valve Fan1 (+) Fan2 (+) Gas Valve Brights led (+) PFC control (+) Inrush relay Brights led (-) PFC control (-) Inrush relay Description Fan 1 (-) Fan 2 (-) Gas valve Fan 1 (+) Fan 2 (+) Gas valve Brights led card (P002) (+) connection. PFC ON/OFF control (+) connection Inrush relay connection Brights led card (P002) (-) connection. PFC ON/OFF control (-) connection Inrush relay connection Pin X5:1 X5:2 Signal PRIM_OV_P PRIM_OV_N Description Primary over voltage alarm (+) Primary over voltage alarm (-) Pin X6:1 X6:2 X6:3 X6:4 X6:5 X6:6 Signal PWM drive B PTC gnd Start B PWM drive A PTC Start A Description IGBT driver transformer other end PTC ground connection Gun switch connection IGBT driver transformer other end PTC connection Gun switch connection Pin X7 Signal Connections to chassis ground Pin X8 Signal Used in development purposes, do not connect anything here Pin X10 Signal Maintenance use Pin X16 Signal Panel card P001 connection Pin X19 Signal Not in use Kemppi Oy 21 (32) SERVICE MANUAL KEMPACT RA 7. PANEL CARD P001 • Panel card is connected to the control card A001 connector with 16-wire ribbon cable 7.1. Connectors Pin X1:1 X1:2 X1:3 X1:4 X1:5 X1:6 X1:7 X1:8 X1:9 X1:10 X1:11 X1:12 X1:13 X1:14 X1:15 X1:16 Signal +24V SDA +5V GND SCL GND Pot_1_A Pot_1_B GND Pot_2_A Pot_2_B GND Pot_3_A Pot_3_B +5V +24V Kemppi Oy Description +24V supply voltage for the LCD backlight I2C bus data +5V supply voltage Ground I2C clock Ground Pulse potentiometer 1 channel A Pulse potentiometer 1 channel B Ground Pulse potentiometer 2 channel A Pulse potentiometer 2 channel B Ground Pulse potentiometer 3 channel A Pulse potentiometer 3 channel B +5V supply voltage +24V supply voltage for the LCD backlight 22 (32) SERVICE MANUAL 23 (32) KEMPACT RA 8. OPERATIONAL MEASURINGS AND TESTS NOTE ! Main supply voltage must not be connected when making measuring operations. The component frame has to be uninstalled so that main components conditions can be measured. 8.1. Kempact 181, 251 V24,25 V1 8.1.1 Primary rectifier V24, 25 • • • Primary side primary rectifier diodes can be measured one at the time Diodes must be measured both forward bias and reverse bias condition to make sure they are fine Check the diodes using the multimeter diode function to measure their threshold voltage 0,3…0,6 V Measurings : 1) Positive test pole to rectifier pole (1, red), negative test pole to rectifiers poles (1, black) one at time Result: 0,3…0,6diodes Ok 2) Negative test pole to rectifier pole (2, black), positive test pole to rectifier poles (2, red) one at the time Result: no valuediodes Ok 3) Negative test pole to rectifier pole (3, black), positive test pole rectifier poles (2, red)one at the time Result: 0,3…0,6diodes Ok 4) Positive pole to rectifier pole (4, red), negative test pole to rectifier poles (1, black) one at the time Result: no valuediodes Ok NOTE ! The measurement procedure is same for V24 and V25 rectifiers. Kemppi Oy SERVICE MANUAL 24 (32) KEMPACT RA 8.1.2. IGBT module V1 • • IGBT module can be tested by multimeter if using the diode tester function. Module holds six diodes and in many cases they may be defective if IGBT is damaged When measuring IGBT unit diodes you must disconnect other end of main transformer (X7) o After measuring connect other end (X7) back Measurings: 1) Negative test pole (1, black) to connector X16, positive test pole (1, red) to connectors X7, X8 and X14 one at time Result: 0,3…0,6diodes Ok 2) Positive test pole (2, red) to connector X13, negative test pole (2, black) to connectors and X7, X8 and X14 one at time Result: 0,3…0,6diodes Ok Kemppi Oy SERVICE MANUAL 25 (32) KEMPACT RA 8.2. Kempact 253, 323 V1 8.2.1. Primary rectifier, V1 • • • Primary side primary rectifier diodes can be measured one at the time Diodes must be measured both forward bias and reverse bias condition to make sure they are fine Check the diodes using the multimeter diode function to measure their threshold voltage 0,3…0,6 V Measurings: 1) Positive test pole to DC-link (-), negative test pole to L1, L2, L3 (one at the time) Result: 0,3…0,6diodes Ok 2) Positive test pole to DC-link (+), negative test pole L1, L2, L3 (one at the time) Result: no valuediodes Ok 3) Negative test pole to DC-link (+), positive test pole L1, L2, L3 (one at the time) Result: 0,3…0,6diodes Ok 4) Negative test pole to DC-link (-), positive test pole L1, L2, L3 (one at the time) Result: no valuediodes Ok Kemppi Oy V2 SERVICE MANUAL 26 (32) KEMPACT RA 8.2.2. IGBT module, V2 • • IGBT module can be tested by multimeter if using the diode tester function. Module holds four diodes and in many cases they may be defective if IGBT is damaged When measuring IGBT unit diodes you must disconnect other end of main transformer (X7) o After measuring connect other end (X7) back Measurings: 1) Positive test pole to connector X7 and X8 one at time, negative test pole to DC link (+) Result: 0,3…0,6diodes Ok 2) Positive test pole to DC-link (-), negative test pole to X7 and X8 one at time Result: 0,3…0,6diodes Ok Kemppi Oy SERVICE MANUAL 27 (32) KEMPACT RA 8.3. Secondary rectifier card, Z002 • Use a digital multimeter to test the secondary unit diodes. Diodes are in groups, so you can measure them in two separate groups Measurings: 1) Positive test pole to main transformer secondary (secondary card connectors X1 and X2 one at time), negative test pole to secondary profile Result: 0,3…0,6diodes Ok 2) Positive test pole to secondary profile, negative test pole to main transformer secondary (secondary card connectors X1 and X2 one at time) Result: no valuediodes Ok Kemppi Oy SERVICE MANUAL 28 (32) KEMPACT RA 3) Snubber resistors R3 and R4 Result: value ~10 Ω 8.4. PTC’s, overheat protection • There are two PTC’s in machine o Main transformer Rt101 140 °C, value ~94 Ω in room temperature (connector 12, blue/white) o Secondary profile Rg201 90 °C, value ~63 Ω in room temperature (connector 11, green/green) o In over temperature situation PTC goes to high-resistance mode (>10kΩ) o A broken PTC has usually hundreds of kilo ohms resistance or no value at all 8.5. Control card A001 • Control card voltages can be quickly verified with LEDs on the control card A001 9. MAIN COMPONENTS INSTALLATION • • Heat sink paste should be spread on to the modules in an even layer by using clean fingers. Then the card should be immediately mounted onto the heat sink, this minimizes the possibility of any contamination (dirt etc.) getting between the components. Use torque screwdriver when tightening any power components onto the heat sink. See following sections for tightening torques. 9.1. Main circuit card Z001 • • • • Primary rectifier V1 to heatsink 2 NM IGBT unit to heatsink o First step 2 NM and wait a couple minutes o Second step 3 NM Main circuit card Z001 to profile holder 0,7 NM Primary unit to component frame 2 NM Kemppi Oy SERVICE MANUAL KEMPACT RA • Z001 grounding cable to component frame 5 NM 9.2. Secondary rectifier card Z002 • • • • • Secondary diodes to heatsink 1,2 NM Resistors to heatsink 0,7 NM Secondary card Z002 to heatsink 2,5 NM Secondary profile to component frame 2 NM Main transformer secondary leads 5 NM 9.3. Other components • • • • • • Main transformer T001 to component frame 2 NM Main transformer T001 secondary leads to secondary card Z002:X1,X2 5 NM Rectifier G003 to component frame 5 NM Auxiliary transformer T002 to component frame 5 NM Secondary choke L001 to component frame 2 NM Secondary choke L001 other lead to secondary profile 5 NM and other lead to polarity screw 5 NM Kemppi Oy 29 (32) SERVICE MANUAL 30 (32) KEMPACT RA 10. ERROR CODES • • • In error situation welding is stopped and an error code is displayed on the panel The user can clear the error by pressing any of the panel buttons and if certain conditions are fulfilled If there are multiple errors at the same time only one can be displayed at a time. After user has cleared one error next is displayed and so on until there is no more errors Error code 2 Error Mains under voltage 3 Mains over voltage 4 Wire feed motor over current 5 Wire feed motor control not calibrated -calibration parameters have been corrupted -faulty control card A001 6 Power source control not calibrated -power source control calibration parameters are not in predefined limits -calibration parameters have been corrupted -faulty control card A001 -start up machine (on/off) - change control card A001 7 User interface memory error -start up machine (on/off) -check welding parameters 8 Memory channel 1 error -EEPROM memory error -used wrong welding parameters (improper value) -memory channel data is invalid / corrupted 9 Memory channel 2 error -memory channel data is invalid / corrupted 10 Memory channel 3 error -memory channel data is invalid / corrupted 11 Memory channel 4 error -memory channel data is invalid / corrupted 12 Continuous short circuit in the output of the power source -there is continuous (over 2s.) short circuit in the output of the power source. 100 Microcontroller error 101 Microcontroller error 102 Microcontroller error 103 Microcontroller error 110 Panel communication error 111 Panel communication error 112 Panel communication error -microcontroller reset. Possible reason: tig ignition spark. -microcontroller reset. Possible reason: flash memory has been corrupted -microcontroller reset. Possible reason: electromagnetic disturbance -microcontroller reset. Possible reason: electromagnetic disturbance -communication error between panel card P001 and control card A001 -communication error between panel card P001 and control card A001 -communication error between panel card P001 and control card A001 Kemppi Oy Reason -mains voltage is under lower limit. -181 model: 195 V -251 model: 204 V -253, 323 models: 340V -mains voltage is over high limit: -181 model: 265 V -251 model: 276 V -253, 323 models: 460V -wire feed motor current (6 amps longer than 60 s) is too high -motor is jammed longer than 60 s Action / remedy -check mains voltage -mains over voltage error can be cleared after mains voltage has risen over low limit. -check mains voltage -mains over voltage error can be cleared after mains voltage has fallen under high limit -this error can be cleared after welding has stopped due to this error -check wire feeding motor and mechanism -start up machine (on/off) -change control card A001 -start up machine (on/off) -check welding parameters -start up machine (on/off) -check welding parameters -start up machine (on/off) -check welding parameters -start up machine (on/off) -check welding parameters -remove short circuit from machine output (contact tip is connected / short circuited in welding piece) -start up machine (on/off) -start up machine (on/off) -start up machine (on/off) -start up machine (on/off) -check flat cable/connectors between panel- and control card -check flat cable/connectors between panel- and control card -check flat cable/connectors between panel- and control card
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Key Features
- Compact MIG/MAG welding machines
- Inverter technology based design
- IGBTs for power switching
- Wire feeder drive circuitry
- Intuitive user interface
- Microcontroller control
- Professional use
- Easy to use