Kemppi 3200 Operating manual

TECHNICAL SERVICE
MANUAL FOR
KEMPOWELD MACHINES

TECHNICAL SERVICE MANUAL FOR KEMPOWELD
GENERAL MAINTENANCE OF KEMPOWELD
Maintenance of Kempoweld power source will normally consist of general cleaning
of unit with soft brush and vacuum cleaner, and checking of wearing for parts like:
switches,connectors, potentiometers and fuses. NOTE! If you use compressed air
for cleaning, there is a risk that dirt is packed even more tightly into gaps of
connectors or components, so be carefull with those parts!
Maintenance of the wire feeder and mig gun will normally consist of general
cleaning and change of consumable parts like: contact tube, contact tip,
contact tip adapter, gas nozzle, wire conduit, feeding rolls, guide tubes, and gear
wheel.
The number of machines in will determine to what extend consumable- and spare
parts will be stocked.
WARNING
Watch out for the mains voltage! Disconnect the power source from mains voltage
before removing cover plates or any testing or measurement and before
troubleshooting look for signs of over heating, fractures and damages from internal
components and power semiconductors.
TROUBLESHOOTING CHART
TROUBLE CAUSE REMEDY
The KEMPOWELD won´t start at all,
any of the auxiliary devices won´t
start.The signal lamps of machine
are not switched on.
Blown fuse in mains supply voltage.
Faulty mains cable.
Broken main switch.
Faulty auxiliary transformer T002 or
bad connection in connector X9,
400V or 0V.
Blown fuse F001 8A.
Check all three supply voltage
phases; check fuses.
Check mains voltage from terminal
block X001, repair cable if needed.
Check the main supply voltage
before and after main switch, change
switch if needed.
Check transformer, repair
transformer connection or change
if needed.
Check fuse and change if needed.
The wire feeding unit K200/400
won´t work.
Faulty connection in control lines.
Blown fuse F001 8A.
Broken PCB.
See, TABLE FOR CONTROL
LINES, table 1.
Check/change fuse F001.
See, TROUBLE SHOOTING FOR
PCBs appendix 1.

TECHNICAL SERVICE MANUAL FOR KEMPOWELD
TROUBLESHOOTING CHART
TROUBLE CAUSE REMEDY
The cooling unit don´t start or pilot
lamp Hw3 lacking water pressure is
iluminated.
Blown fuse F002 2A.
Auxiliary transformer T002.
Pressure switch S005
5µF capacitor C001.
Broken PCB.
Check and change the fuse if
needed.
Check the voltage from transformer
in the terminal block between 2.1
and 2.2, it should be 230v.
Check the voltage over the pressure
guard or from PCB A002 X2/1 and
X2/8; enough pressure 0V and lack
of pressure c. 5V.
Check and change the capacitor if
needed.
See, TROUBLE SHOOTING FOR
PCBs appendix 1.
The solenoid valve Y001 don´t work. Faulty solenoid valve or PCB A001. Check the 24 VDC from connector
X3/5 and X3/6, change valve or
PCB.
Wire feeding motor don´t work. Blown fuse F001 8A
The control cable between feeder
and power souce is broken or it is
not properly tightened.
Faulty motor or PCB A001in
K200/400.
Broken PCB.
Check/change the fuse if needed.
Check and repair the control cable if
needed. See table 1.
Check the motor voltage from A001
X4/12 and X4/13 max. is c. 24 VDC,
if it´s all right motor is faulty.
See, TROUBLE SHOOTING FOR
PCBs appendix 1.
Welding quality is bad:
- arc is not stable
- there are lot of spatters
- bad arc start
- not enough arc voltage
One phase is missing.
Faulty main transformer T001.
Faulty main switch S001 or contactor
K001.
Shielding gas is missing.
Gas hose of the gun is leaking or
connection is loose.
Broken diode in the secondary.
rectifier G001.
Check all phases from the therminal
block X001. Change mains fuse if
needed or tighten mains cables.
Check that voltages are symmetric
over the three spools of T001.
Variation of voltage is depending on
voltage selection and load; normally
it is between 10 VAC and 32 VAC.
OCV variation range is 11 VAC
to 35 VAC
Measure first main switch if it is all
right check the contactor.
Check the valve according the
instructions mentioned above.
Check/repair the mig gun.
Check and change diode(bridge)
if needed.

TECHNICAL SERVICE MANUAL FOR KEMPOWELD
TROUBLESHOOTING CHART
TROUBLE CAUSE REMEDY
Welding stops occasionally or some
other occasional disturbances.
Faulty intermediate cable or
connector.
Faulty switch in mig gun.
Loose start wire(s) in mig gun.
Check/repair the cable. See TABLE
FOR CONTROL LINES, table 1.
Check and change the switch if
needed.
Check and tighten the start wire(s)
inside the gun.
Machine is overheating because the
fan don´t start.
Faulty fan or PCB A001 . Check the 24 VDC voltage from fan
connector X2/12 and X2/13, if it is all
right change the fan, if it is not
change the PCB.
See, TROOUBLE SHOOTING FOR
PCBs appendix 1.
Wire feeding speed set value can´t
adjusted.
The set value potentiometer RW102
is faulty.
Check and change the 10KΩ
set value potentiometer RW102 if
needed.
KMW-sync is not working. Faulty connection in connector X1. Check and repair connection
according to PICTURE 1.
If some other push-pull gun than
Binzel or Hulftegger is in use the gun
is pulling to fast.
Wrong motor voltage. Select correct jumper combination
(there are two jumpers X1 and X2
and the fine adjustment for voltage
can made from MP-SYNC PCB)
from MP-SYNC control card. See
also PICTURE 2.
MSD-1 meter unit don´t work. Ribbon cable between MSD-1 and
control card A001 is loose or cut.
Faulty MSD-1 unit.
Check and tighten the cable, check
also the control voltage for MSD-1
from A001 X3/16 and X3/1 the value
should be 12 V.
Check as mentioned above if it´s all
right, chage the MSD-1.
Occasional disturbances with KMW-
timer unit.
Ribbon cable between KMW-timer
and control card A001 is loose or
cut.
Faulty KMW-timer unit.
Check and tighten the ribbon cable.
Check and change the KMW-timer
unit. See also potentiometers from
PICTURE 3.
The water circulation stops after 5 s
of welding.
Low cooling water volume.
Air bubbles or leakages in cooling
system.
Faulty pressure switch
Check the water and fill it if needed.
Follow the instructions of
Kempoweld Operation Instructions/
Operation Disturbances.
Check/change the pressure switch.

TECHNICAL SERVICE MANUAL FOR KEMPOWELD
TABLE 1. CONNECTORS AND CONTROL LINES
KEMPOWELD CONNECTORS X006 AND K200/400 XW101
XW101 / X006 K200/400
A001
KEPOWELD
A001
VALUE
BX3/1 X8/3 30 VAC
CX3/8 X2/1 30 VAC
DX3/7 X2/11 START
PICTURE 1. KMW-SYNC CONNECTION
A
B
C
D
E
F
G
H
M
HC-start

TECHNICAL SERVICE MANUAL FOR KEMPOWELD
PICTURE 2. A004 MP-SYNC CONTROL CARD
A
004
X
2
X
1
X
3
PICTURE 3. PCB OF K400 TIMER UNIT
R 11
R 15
R 19
X
1
Potentiometers: R11 = Gas post flow
R15 = Cycle time
R 19 = Pause time

TECHNICAL SERVICE MANUAL FOR KEMPOWELD
PICTURE 4. A001 PCB OF K400
Potentiometer: R24 = Adjustment of wire feed speed
V
2
V
3
X3
X
4
X7
X6
C4 C5 C6
C3
R24

TECHNICAL SERVICE MANUAL FOR KEMPOWELD
APPENDIX 1. TROUBLESHOOTING FOR PCBs
A001 POWER SOURCE
1. + 24 V over the capacitor C9
2. + 24 V over the capacitor C7 (FAN POWER SUPPLY)
3. + 15 V over the over the diode V2
4. + 12 V over the capacitor C10 (MSD POWER SUPPLY)
5. START => pin X2/11 to GND, 0V = start active
6. START => V4 to GND, 0V = start active
7. TP 4 = 15 V, FAN ON CONTROL
8. FAN TIMER voltage over C3 under 5 V = stop, over 10 V = on
A001 WIRE FEEDER
1. 30 VAC between the thyristros anodes
2. + 40 V over the capacitor C3
3. + 15 V over the diode V17
4. SYNCRONIZATION TP 19 (rectified sine wave)
5. RAMP WAVE over the capacitor C11 (the wave is only active when start
or wire feeding is on)
6. START TP13; 0V ON, 15 V STOP
7. BREAK CONTROL TP24 ; OV active 15 V stop
8. BURN BACK/POST GAS TIMER TP33; 15 V stop, under 2V on
9. CONTACTOR CONTROL TP 32; under 1 V off, over 5 V on
10. I FAN CONTROL TP 34; under 1 V off, over 10 V on
II FAN CONTROL, voltage over the capacitor C17 < 2 V fan off
< 6V fan on
11. SET VALUE FOR WIRE FEEDING SPEED pin X2/1 and GND; voltage between
0 V - 15 V depending on potentiometer setting

TECHNICAL SERVICE MANUAL FOR KEMPOWELD
A002 WATER COOLING UNIT
1. + 24 V over the capacitor C5
2. + 15 V over the capacitor C6
3. START TP 1 => 15 V
4. PRESSURE SWITCH pin X2/1 to GND; 0V pressure OK, 24 V no pressure
5. THERMAL PROTECTION between pins X2/3 and X2/6; 0.1 V - 0.3 V normal
temperature, over temperature over 3V
6. PUMP TIMER; TP 3 on > 5 V
off < 1 V
TP 18 on ≈0.6 V
off < 0.2 V

KEMPOWELD 2501 7.2.2000/V211203 3144530/1921760
Order no. Part Description Pc.
4279480 A001 CONTROL CARD A001 KWELD3200-4000W 1
3143990 C001 CAPACITOR UNIT KEMPOMAT 2001, 2501 1
9772551 F001 FUSE BOX + NUT 1
9750159 G001 RECTIFICATION UNIT 1
9775729 H001 SIGNAL LAMP YELLOW 1
9764112 K001 CONTACTOR 1
3143880 L001 CHOKE 1
9544213 M001 COOLING FAN MASTER 1500/2200 1
9761225 S001 FLIP-FLOP SWITCH WITH PILOT LAMP 1
9760603 S002 SWITCH 2
3143810 T001 TRANSFORMER KMAT 2501 1
3141290 T002 AUXIL. TRANSFORMER 1
9771530 X003 MACHINE SOCKET DIX BE 50/70 2
4191441 ZG001 RC PROTECTION 1
2070060 001 UNDERCARRIAGE KEMPOMAT, KEMPOWELD 1
2070330 002 FRONT PLATE KEMPOWELD 2501 1
2070080 003 REAR PLATE KEMPOWELD 2501 1
2070340 004 SIDE PLATE LEFT KEMPOWELD 2501 1
2070350 005 SIDE PLATE RIGHT KEMPOWELD 2501 1
3001873 007 CLAMP D30 1
3001875 008 INSULAT. PLATE FOR CLAMP 1
1028120 009 COVER PLATE KEMPOWELD 1
2061410 010 REAR GRATE MASTER 2800/3500 1
9547105 011 WHEEL 2
9547770 012 WHEEL, ROTATING 2
2062900 013 PLASTIC HANDLE 26X50X217/188 1
3138950 015 AXLE INSULATION 1
3144210 CIRCUIT DIAGRAM KEMPOWELD 2501 1

KEMPOWELD 3200 7.3.2000/V215303 3145130/1921830
Order no. Part Description Pc.
4279480 A001 CONTROL CARD A001 KWELD3200-4000W 1
9772551 F001 FUSE BOX + NUT 1
4287570 G001 RECTIFICATION UNIT KWELD3200/4000/4000W 1
4287420 G002 PARALLEL DIODE KEMPOWELD 1
9775729 H001 SIGNAL LAMP YELLOW 1
9764130 K001 CONTACTOR 1
3138510 L001 CHOKE KWELD,KMAT 3200 1
9544214 M001 COOLING FAN MASTER 2800/3500 1
4287840 R001 RESISTOR 0.23 OHM KWELD 1
4266150 R002 SHUNT RESISTOR 300A/60MV 1
9761225 S001 FLIP-FLOP SWITCH WITH PILOT LAMP 1
976052101 S002 SWITCH D22,5 2
2066190 T001 TRANSFORMER KWELD,KMAT 3200 1
3141290 T002 AUXIL. TRANSFORMER 1
9771530 X003 MACHINE SOCKET DIX BE 50/70 2
4191441 ZG001 RC PROTECTION 1
2070060 001 UNDERCARRIAGE KEMPOMAT, KEMPOWELD 1
2070820 002 FRONT PLATE KEMPOWELD 3200 1
2070790 003 REAR PLATE KEMPOWELD 3200/4000 1
2070800 004 SIDE PLATE LEFT KEMPOWELD 3200, 4000 1
2070810 005 SIDE PLATE RIGHT KEMPOWELD 3200, 4000 1
3001873 007 CLAMP D30 1
3001875 008 INSULAT. PLATE FOR CLAMP 1
1028120 009 COVER PLATE KEMPOWELD 1
2061410 010 REAR GRATE MASTER 2800/3500 1
9547105 011 WHEEL 2
9547770 012 WHEEL, ROTATING 2
3138950 015 AXLE INSULATION 1
4279940 016 FLAT CABLE L=380 1
2062900 017 PLASTIC HANDLE 26X50X217/188 1
3139040 CIRCUIT DIAGRAM KEMPOWELD 3200 1