Service manual
v. 1.0
FastMig
KM 300
KM 400
KM 500
KMS 300
KMS 400
KMS 500
MF 29
MF 33
MSF 53
MSF 55
MSF 57
1
Table of contents
Technical data
Fastmig KM / MF............................................................................. 3
FastMig KMS / MFS........................................................................ 4
Fastmig KMS / MVU........................................................................ 5
Main circuit diagram
KM.................................................................................................... 6-7
MF.................................................................................................... 8
KMS................................................................................................. 9
MSF................................................................................................. 10
KM / MVU........................................................................................ 11
KMS / MVU..................................................................................... 12
Block diagram.................................................................................................... 13
Main circuit card Z001 KM / KMS
Operating diagram...........................................................................14
Operation principle.......................................................................... 15
Connectors...................................................................................... 16
Operational measurings.................................................................. 17
Capacitor card Z002
Operating diagram.......................................................................... 18
Connectors..................................................................................... 18
Secondary rectifier card Z003
Operating diagram.......................................................................... 19
Connectors..................................................................................... 19
Operational measurings................................................................. 19
Control card A001
Operating diagram.......................................................................... 20
Connectors..................................................................................... 21-22
Operation of the LEDs on control card........................................... 22
Motor control card A002
Operating diagram.......................................................................... 23
Connectors..................................................................................... 24
ID-chip card A002 (MSF)
Connectors..................................................................................... 25
Panel card P001
Operating diagram.......................................................................... 26
Connectors..................................................................................... 26
Error codes........................................................................................................ 27
Setup menu....................................................................................................... 28
Wire feed speed calibration / KM.................................................................... 29-30
Structure
KM / KMS....................................................................................... 31-32
MF.................................................................................................. 33
MFS................................................................................................ 34
IGBT testing....................................................................................................... 35
IGBT replacing................................................................................................... 36
2
Technical data
FastMig KM / MF
3
Technical data
FastMig KMS / MSF
4
Technical data
FastMig KMS / MVU
5
Main circuit diagram
R001
Varistors
L001
Choke
S001
Main switch
Z002
Capasitor card
Z001
Main circuit card
PTC
T001
Main transformer
PTC
PTC
Z003
Secondary card
L001
Secondary choke
RC001
RC-protection
G003
Diode bridge
T002
Aux. transformer
M001
Cooling fan
A001
Control card
F001
Fuse 6,3 A
H001 / 002
Leds
A002
Control card
P001
Panel card
KM-power sources (A002)
also contain circuitry that is needed for wire feeding motor driving and reading of the potentiometer of the simple wire feeder (MF or other).
6
Main circuit diagram KM
7
Main circuit diagram MF
8
Main circuit diagram KMS
9
Main circuit diagram MSF
10
Main circuit diagram KM / MVU
11
Main circuit diagram KMS / MVU
12
Block diagram
Control card A001
•Microcontroller
•PWM circuit
•Secondary voltage measurement
•Secondary current measurement
•IGBT driver
•Auxiliary device connection
•Auxiliary power supply
•Machine size jumpers
(J1, J2)
•Primary current limit jumpers
(J3, J4, J5)
•Operational jumpers
•LED’s
•Water cooler connection
Control card A002
•WF-motor control
•Connection to the panel card P001
•Remote controller connection
•MIG gun connection
•Solenoid valve connection
•Fuse
Panel card P001
•Main micro controller
•User interface (buttons, potentiometers, displays, LED’s)
•Connection to the A002
Main circuit card Z001
•EMI filtering
•Three phase rectifier (V6)
•Switching-ON transient suppression
•Power Stage
•Current transformer (T1)
Capasitor card Z002
•Energy storage
•Discharging
Secondary card Z003
•Rectifying
•Snubber
•Protection against HF
13
Main circuit card Z001 KM / KMS
DC-link (+)
From main switch
DC-link (-)
Operating diagram
- EMI filtering
- Three phase rectifier (V6)
- Switching-ON transient suppression
- Power Stage
- Current transformer (T1)
14
IGBT gates
Main transformer primary coil
Main circuit card Z001
Operation principle
Approx.. + 570 V
G1
U
G1
G2
U
G2
G5
U
T1
L1
U
G5
U
L1
G3
U
G3
U
G1
U
G2
U
G3
U
G4
U
T1
G4
U
G4 t t t t t
U
G5 t
U
L1 t
When IGBT-transistors G1 and G4 conduct, there is a positive voltage U
T1
in main transformer T1 primary and when IGBT-transistors G2 and G3 conduct there is a negative voltage U
T1
Power is adjusted by changing the IGBT timings (PWM) in main transformer primary.
15
Main circuit card Z001
Connectors
Z001 connectors / signals
X1
Main switch
X2
Main switch
X3
Main switch
X4
Chassis ground
X5
Chassis ground
X6
Main transformer
X7
Main transformer
X8
IGBT gates and emitters
X9
IGBT gates and emitters
X10
IGBT gates and emitters
X11
IGBT gates and emitters
X12
IGBT gates and emitters
X13
IGBT gates and emitters
X14
IGBT gates and emitters
X15
IGBT gates and emitters
X19 X21
X6
X37
X36
X7
X17
X16
X3
X2
X4 X1 X5
Z001 connectors / signals
X16
Primary choke
X17
Primary choke
X18
DC-link voltage (+)
X19
DC-link voltage (+)
X20
DC-link voltage (-)
X21
DC-link voltage (-)
X29
Chassis ground
X36
Current transformer secondary
X37
Current transformer secondary
X40
Auxiliary transformer
X41
Auxiliary transformer
X15
X14
X11
X10
X13
X12
X9
X8
X20
X18
X40
X41
X29
16
Main circuit card Z001
Operational measurings
A
B
A.
Main transformer T001 primary voltage, set values 50 A/16,5 V
B.
IGBT-gate pulses, set values 50 A/16,5 V
17
Capacitor card Z002
Operating diagram
X3 X1
- Energy storage
- Discharging
Connectors
Z002 connectors / signals
X1
DC +
X2
DC +
X3
DC -
X4
DC -
X4 X2
18
Secondary rectifier card Z003
Operating diagram
X5
X1
X6 X7
Z003
X2
X3
X8
X4
- Rectifying
- Snubber
- Protection against HF
Connectors
Z003 connectors / signals
X1
Main transformer
X2
Main transformer
X3
Main transformer
X4
Main transformer
X5
Secondary choke
X6
Secondary choke
X7
Secondary choke
X8
Secondary choke
Operational mesurings
X5-X8
X1-X4
C
X003, machine (-) pole
X5
X1
X6
X7
Z003
X2
X3
X8
X4
C.
Voltage after secondary rectifier card Z003, set values 50 A/16,5 V
19
Control card A001
X5
X4
H2
X1
H1
X3
X2
F1
F2
H4
Operating diagram
X6 X7 X9
X8
X10
H7
X17
H8
X15
X14
X13
X16
H10
H9
X11
- Microcontroller
- PWM circuit
- Secondary voltage measurement
- Secondary current measurement
- IGBT driver
- Auxiliary device connection
- Auxiliary power supply
- Machine size jumpers (J1, J2)
- Primary current limit jumpers (J3, J4, J5)
- Operational jumpers
- LED’s
- Water cooler connection
20
Control card A001
Connectors
A001 / X1
X1
DC-link voltage (+)
A001 / X2
X2/1 20V auxiliary voltage~
X2/2 20V auxiliary voltage ground
X2/3 20V auxiliary voltage~
X3/1 IGBT emitter
X3/3 IGBT emitter
X3/4 IGBT gate
X3/6 IGBT gate
A001 / X3
X4/1 IGBT emitter
X4/3 IGBT emitter
X4/4 IGBT gate
X4/6 IGBT gate
A001 / X4
A001 / X5
X5/1 Fan (-) (M002)
X5/2 Fan (+) (M002)
A001 / X6
X6/1 Fan (-) (M001)
X6/2 Fan (+) (M001)
A001 / X7
X7
Production programming bus
A001 / X8
X8/1 Current transformer ~
X8/3 Primary current limit jumper (J3)
X8/4 Primary current limit jumper (J4)
X8/5 Primary current limit jumper (J5)
X8/6 GND
X8/7 Current transformer ~
X8/9 GND (Primary current limit jumper J3)
X8/10 GND (Primary current limit jumper J4)
X8/11 GND (Primary current limit jumper J5)
X8/12 GND
A001 / X9 / KM
X9/1 System bus DATA
X9/2 System bus DATA B
X9/3 GND
X9/4 + 50 V
X9/6 -
X9/7 -
X9/8 -
X9/9 -
X9/10 Connection A002 X1/4
X9/11 -
A001 / X9 / KMS
X9/1 System bus DATA B
X9/2 System bus DATA B
X9/3 +50V
X9/4 +50V
X9/6 +5V
X9/7 +5V
X9/8 Analog DATA
X9/9 Analog DATA
X9/10 GND
X9/11 GND
A001 / X10
X10/1 Shunt (+)
X10/2 -
X10/3 Secondary voltage (+)
X10/4 -
X10/5 Machine size jumper J1
X10/6 Machine size jumper J2
X10/7 Shunt (-)
X10/8 TxD0 (possible future use)
X10/9 RxD0 (possible future use)
X10/10 GND
X10/11 GND(Machine size jumper J1)
X10/12 GND(Machine size jumper J2)
(X005)
(X006)
(X005)
(X006)
(X005)
(X006)
(X005)
(X006)
(X006)
(X005)
A001 / X11
-
Not connected
J6
Forced programming mode
J7
For future purposes
J8
For future purposes
J9
For future purposes
21
Control card A001
Connectors
A001 / X13
X13/1 PTC, Rg 101 (Z001)
X13/2 PTC, Rg 101 (Z001)
A001 / X14
X14/1 PTC, Rt 101 (T001)
X14/2 PTC, Rt 101 (T001)
A001 / X15
X15/1 PTC, Rg 201 (Z003)
X15/2 PTC, Rg 201 (Z003)
A001 / X16
X16/7 H002 + (yellow led)
X16/8 H002 -
X16/9 H001 + (green led)
X16/10 H001 -
A001 / X17
X17/1 +24V
X17/2 CLU_fault
X17/3 GND
X17/4 CLU_AD_CH1
X17/5 CLU_AD_CH2
X17/6 ON/OFF
Operation of the LEDs on control card
A001 / LEDS
H1
IGBT gate pulses
H2
IGBT gate pulses
H3
IGBT gate pulses
H4
IGBT gate pulses
H5
+15V
H6
+5V
H7
Remote control unit connected
H8
Data communication
H9
Micro controller operation
H10
Micro controller operation
H1-H4: Indicate the existence of the gate pulses.
H5, H6: Indicate that auxiliary voltages exist (+5V and +15V). If these Leds are not lit when the power source is switched on, first thing to do is check if control card fuses are OK.
H7, H8: Indicate operation of the auxliary device connection. LED H8 indicates that there is data communication taking place through the system bus when it is lit. LED H7 indicates that remote control unit is connected when it is lit.
H9, H10: Indicate state of the microcontroller. In normal situation both leds should be lit.
22
Motor control card A002
X4
Operating diagram
X3 X1 X2
- WF-motor control
- Connection to the panel card P001
- Remote controller connection
- MIG gun connection
- Solenoid valve connection
- Fuse
- ID-Chip connection (MSF)
23
Motor control card A002 (A001 = MSF)
Connectors
A002 / X1 / KM
X1/1 Connection to A001, X9/4
X1/4 Connection to A001, X9/10
A001 / X1 / MSF
X1/1 Bus +50V
X1/3 Tacho +5V
X1/4 Bus GND
X1/5 Tacho GND
X1/6 Tacho Signal
A002/A001 / X2
X2
Connection to panel card
A002 / X4 / MF
X4/2 Start
X4/3 Motor+
X4/4 U-measurement
X4/6 Pot +5V
X4/8 Connection A001 X9/2
X4/11 WF-pot
X4/12 Valve
X4/14 GND
X4/15 Motor -
A001 / X4 / MSF
X4/1 Pot GND
X4/2 Start 2
X4/3 Motor +
X4/4 Pot 2
X4/5 Start 1
X4/6 Pot +5V
X4/7 ID Bus 2
X4/8 Bus Data
X4/9 General I/O
X4/10 Valve -
X4/11 Pot 1
X4/12 Valve +
X4/13 ID Bus 1
X4/14 GND
X4/15 Motor -
24
ID chip card A002 (MSF)
A002
ID-chip card
Connectors
A002
TP1
ID Bus 1 (connection to A001)
TP2
ID Bus 2 (connection to A001)
25
Panel card P001 / KM
Operating diagram
- Main micro controller
- User interface (buttons, potentiometers, displays, LED’s)
- Connection to the A002
Connectors
P001 / X2
X2
Connection to A002
26
Err 153:
Err 154:
Err 155:
Err 161:
Err 162:
Err 171:
Err 172:
Err 173:
Err 184:
Err 185:
Err 201:
Err 221:
Err 222:
Err 223:
Err 224:
Err 225:
Err 241:
Err 251:
Err 252:
Err 254:
Err 15:
Err 21:
Err 22:
Err 23:
Err 31:
Err 54:
Err 55:
Err 61:
Err 2:
Err 3:
Err 4:
Err 5:
Err 11:
Err 12:
Err 13:
Err 14:
Err 255:
Err 999:
Error codes
Power source
MIG Logic
Curve Access
Robot Interface
MIG / TIG Unit
User interface
Others
1 ..... 50
51 ….. 100
101 ….. 130
131 ….. 150
151 ….. 200
201 ….. 250
0 ….. 999
Power source undervoltage ( new start up )
Power source overvoltage ( new start up )
Power source is overheated
Water unit alarm
Two units have the same address in the system bus
Data error on communication (2)
Member of a wrong FastMIG family connected
Data communication problem between power source and auxiliary unit
Power source program / updating method problem
Power source´s control card +5 V aux. Voltage too low
Power source´s control card +15 V aux. Voltage too low
Temporarily power source overvoltage
Power source calibration error. Welding only possible with default values.
No data communication from power source. Perhaps faulty cable/connector.
Welding forbidden (congiguration / system bus reserved)
The water unit is not found. Cooling unit may be OFF.
Overheating of liquid-cooled gun
Wire feed motor overcurrent. Perhaps the wire liner is blocked or gun cable too curvy.
Wire feed motor overload. Motor´s current is too close to the limit.
Warning of the wire feed unit overheating
Overloading of the wire feed motor
Configuration of the equipment can not be found. Gun start wires cross-connected.
Wrong configuration code has been supplied
Operation is not activated with right configuration code
Control cable not connected or faulty.
Machine program update error. Wrong program or updating method.
Usage of PMT-gun prevented
Data error of the panel (1)
Data error of the panel (2)
Data error of the panel (3)
Data error of the panel (4)
Program updating problem.
EEPROM is faulty
DLI data communication error(another unit in the bus is using same code=conflict)
DLI data error (2)
DLI data communication error(connection to other units has been interrupted(maybe bad connectors or cable damages)
DLI data communication error(program update problem, maybe a wrong program version etc)
Unidentified error (systembus has sent an error message not identified by the panel)
27
Setup menu
MF 29 / 33
FastMig Basic (MF) SETUP menu
SF 51, 52, 53, 54
Normal MIG
1-MIG
FR-MIG
All MIG processes
MMA
FastMig Synergic (MSF) setup menu
28
Wire feed speed calibration / KM
• In factory set Wfs is adjusted in the range of 4...100 without any unit
• LED light and feed roll symbol tells that the parameter to be set is Wfs
• After Wfs Calibration m/min unit is displayed
• Drive filler wire through the MIG gun and contact tip
• Enter to User Setup Menu by pressing SETUP button ( appr 5 s )
• Select the Calibration menu ( CAL ) with left side potentiometer
• Select "Enter" ( Ent ) with right side potentiometer
• Approve your selection by pressing briefly REMOTE / LOCAL key
• Select 'm/min' as calibration value of the quantity with right side potentiometer
• Approve selection by pressing briefly REMOTE / LOCAL key
• Set first Calibration point (e.g. 2.0 m/min ) with left side potentiometer
1. Press MIG gun trigger and let the wire run until it stops automatically
2. Measure the length of feeded wire with the accuracy of 1 cm
3. Enter wire length to the panel display ( cm ) with right side potentiometer
4. Approve your selection by pressing briefly REMOTE / LOCAL button
• Set second Calibration point (e.g. 18.0 m/min )
• Repeat steps 1 - 4 with left side potentiometer
• Message "Suc cES" in the display inform that calibration has ended successfully
• After Calibration panel returns to the operation mode
29
Wire feed speed calibration
If wire feeding speed is not correct (too slow or too fast), motor control card A002 must be calibrated by following instruction:
• Set ‘MIN’ and ‘MAX’ -trimmers to middle position.
• Set ‘IR-comp’ -trimmer to clock vice maximum.
• Set wire feeding speed to maximum from the panel (Basic: 100, Synergic: 25,0 m/min). Adjust ‘MAX’ –trimmer until wire feeding speed is same than value adjusted from the panel.
• Set wire feeding speed to minimum from the panel (Basic: 4, Synergic: 1,0 m/min). Adjust ‘MIN’ –trimmer until wire feeding speed is same than value adjusted from the panel.
• Check/adjust minimum and maximum again until both are OK.
• If adjustment range is too small, decrease IR -compensation and adjust minimum and maximum again.
R87 max.
IR comp
R24 min
30
Structure
KM / KMS
Mains connector and varistors
Z001
Main circuit board
Z002
DC-link
Capasitor board
A001
Control card
S001
Main switch
R001
Shunt resistor
P001
Panel card
A002 (KM)
Wire feed control card
Water cooler
Power connector
31
Structure
KM / KMS
T002
Auxiliary transformer
L002
Secondary choke
Capacitors and varistors
L001
Choke
Z003
Secondary rectifier diodes
32
Structure
MF 29 / 33
Dura Torque wire feeding mechanism
Axle for wire reel coop
Control cable connector
& wiring
Solenoid valve
Welding gun connection
Welding current connector
& copper bar
Dura Torque wire feeding mechanism
33
Structure
MSF 53 / 55 / 57
A001
Motor control card
A002
ID-chip card
34
IGBT testing
C1/3
B1/4
X14
G3
X12
G1
B2/6
X10
G4
X8
G2
X6
X15
E3
X13
E1
X6
X7
C2E1/1
X11
E4
X9
E2
X7
E2/2
C1/3
B1/4
X14
G3
X12
G1
B2/6
X10
G4
X8
G2
E2/2
X15
E3
X13
E1
X6
X7
C2E1/1
X11
E4
X9
E2
C1
E2
X15
X14/G3
X11/
X10/G4
X13
X12/G1
X9
X8/G2
G C E
C1/3
B1/4
35
IGBT replacing
Mounting the IGBT to the heat sink
The tools and premises used in this work must be clean and free of dirt and dust. Even very small particles (0,050mm) between the surfaces may increase the gap between heatsink and module, causing overheating ans possible damage.
Heat transfer compound is to be spread in even layer of approximately 0,1 mm onto the module base. Then the module should be immediately mounted on the heatsink, in order to minimize the possibility of dirt getting between the components.
Firts, all the M5 type screws are tightened 0,5...2 NM. After a few minutes the module can be tightened into the torque of 3 NM.
36
