Kemppi 3200 User manual

Service manual
Ver. 1.0
FEED 400

Contents
General…………………………………………………….3
Technical data………………………………...…………...3
Switches and connectors………………………….………4, 5
Operation principle……………………...………………..5
IGBT-module control………...…………………………. 6, 7
Voltage after secondary diodes…………..…………...... 8, 9
Troubleshooting/diagram…………………...…………...10-12
Wire feeder´s error codes……………………….……….12
Signals between power source and wire feeder………...13-15
Solenoid valve control…………………………….………16
Wire feed motor control.………………………….……...16
Torch connection……….………………...……………….17, 18
Signals from Wf-unit´s connectors…...………………….19
Cooling unit control……………….……………………...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..……………………...………...22
Notes……………………………………...………………..23
2

Kempomig-power sources are 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.
General
Technical data
Supply voltage 3~ 50 / 60 Hz 400 V +10….-15 % 3~ 50 / 60 Hz 400 V +10….-15 %
Connection power 13,4 kVA / 320 A (50 % ED) 18,4 kVA / 400 A (40 % ED)
Supply cable/fuses 4 x 2,5 S / 16 A slow 4 x 2,5 S / 16 A slow
Loadability 320 A / 32,8 V (50% ED)
250 A / 30,0 V (100% ED) 400 A / 36,0 V (40% ED) 250 A / 30,0 V (100% ED)
Welding current adj. range 10 A – 320 A (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)
OCV approx. 75 V approx. 75 V
Idling power < 55 W < 55 W
Degree of protection IP 23C IP 23C
Measures
Length 940 mm 940 mm
Width 515 mm 515 mm
Height 880 mm 880 mm
3200 4000
Water tank volume 3 l
Cooling power 620 W
Max. pressure 400 kPa
Max. flow 4 l / min.
3200W/4000W
Supply voltage 30 Vac 50/60 Hz (150 VA)
Loadability 60% ED
100% ED
400 A
310 A
Wf-speed 0,5…18/25 m/min
Wire spool (max) 20 kg (φ300 mm)
Weight 15 kg
Measures Length
Width
Height
570 mm
210 mm
440 mm
FEED 400
3

1
2
3
4
5
6
7
8
9
10
11
12
13
14 15 16
17
18
19
20
21
22
23
24
25
Switches and connectors
1 Process selection
2 Local / remote control selection
3 Wire feed speed-/ plate thickness display
4 Wire feed speed -/ power adjustment
5 Voltage -/arc length -/ current setting
6 Local / remote control
7 Voltage -/ current set value display
8 Dynamis adjustment, MIG/MAG
9 Synergic program number
10 On/off-signal lamp
11 Overheat signal lamp
12 Dynamics adjustment, MMA
13 Cooling method selection
14 MSD 1-meter unit
15 Coolant overheat signal lamp
16 Cooling unit test switch
17 Missing pressure signal lamp
18 Main switch S001
19 Welding current connection
20 Welding current connection
21 Control connection (amphenol 10-pin)
22 Control connection fuse 6,3 A, slow
23 Cooling unit fuse 2 A, slow
24 Coolant connector, pressure
25 Coolant connector, return
4

1
2
3
456789
H
L
1
3
2
1 2 3
1 Synergic program selection
2 Crater fill on/off
3 Post current 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 conductive 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. UG2
t
UG3
t
U1
t
U2
t
C2
C3
V2
V3
T1
U1
U2
UG2
UG3
approx. + 570 V
5

IGBT-module control
B
A
A
B
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
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
A
B
6

IGBT-module control
B
A
A
B
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
A
B
7

Voltage after secondary diodes
C
C = Voltage after the secondary diodes
(10 A / 20,4 V, MMA)
Frequency approx. 35 kHz
C
CC = Voltage after the secondary diodes
(100 A / 24,0 V, MMA)
Frequency approx. 35 kHz
8

Voltage after secondary diodes
C
C = Voltage after secondary diodes
(320 A / 32,8 V, MMA)
Frequency approx. 35 kHz
C
CC = Voltage after secondary diodes
(400 A / 36,0 V, MMA)
Frequency approx. 35 kHz
9

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.
DISTURBANCE POSSIBLE CAUSE REMEDY
The machine won´t start. WF-
unit´s displays remain blank. Net fuse has blown
Faulty supply cable
Faulty main switch
Faulty aux. transformer
Faulty intermediate cable
Check the net fuses
Check the supply cable
Check the main switch
Check the aux. transformer
Check the intermediate cable
between power source and wf-unit
The fuses blow during machine
startup. A faulty primary side power semiconductor
A faulty main circuit card
A faulty aux. transformer
A faulty secondary unit
Check the primary rectifier and
IGBT-module condition
Check the load capacitors. See, if
there are marks of insulation
damages on the main circuit card.
Check the aux. transformer
Check the secondary diodes
The machine welds, but displays
remain blank. Faulty flat cable
Faulty operating panel
Check flat cables & connectors
between control card A001 and
operating panel.
Replace the operating panel
Power source stays on MMA,
even though MIG is selected by
the panel.
Faulty flat cables
Faulty synergy card P002
Check flat cables & 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.
Troubleshooting diagram
10