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

DISTURBANCE POSSIBLECAUSE REMEDY
Error code E08 is shown on the
panel display Faulty welding gun
Faulty wf-unit control card
A001
Check the welding gun condition
Check the wf-unit´s zener diodes
V27 and 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
The equipment welds ok on spray
arc values, but on short- and
globular-arc it is impossible to
weld
Faulty intermediate cable
Check the intermediate cable
between wf-unit and power source
and see that the process selection
works ok (I-line)
The power source doesn´t start
the cooling unit Faulty intermediate cable
Faulty power source control
card A001
Faulty power source control
A002
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
A001´s connector X7
If the signals on control card A001
connector X7 are ok, then replace
the control card A002
The equipment welds poorly on
short- and globular arc Power source´s control card A001 See, if there is a resistor R188 mounted onto the control card
A001. If one is found, remove it.
The arc is intermitted and
overheat signal lamp is flashing
at the same time
DC-link overvoltage 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.
Wf-unit doesn´t control the
power source Faulty intermediate cable
Faulty aux. transformer
Faulty control card A001
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 A001
11

DISTURBANCE POSSIBLE CAUSE REMEDY
The power source can´t reach
maximum output Net fuse has blown
A faulty supply cable
A faulty main switch
A faulty primary rectifier
A faulty control card A001
A faulty control card A001
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.
Wire feed unit error codes
E02 Gun switch is being pressed, while MMA welding has been selected by the FEED
panel
E08 Liquid cooled PMT-gun has overheated
E09 Wf-motor has been overloaded
E11 PMT-gun has been tried to use, though PMT-/RMT-functions have been disabled
by jumper 5
E12 Shielding gas watch has interrupted welding (GG 400)
12

Signals between power source and wire feeder unit
Pin Signal Explanation
A - -
B 30 Vac Supply voltage for wire feeder unit (fuse 6,3 A slow)
C 30 Vac Supply voltage for wire feeder unit (fuse 6,3 A slow)
D - -
E Power source size / Arc
on Power source size detection / Arc on-info to the wf-unit
F 0 V GND
G - -
H 0 - 10 V Set value information to thepowersource (current or voltage)
I Process selection /
MIG/MAG-dynamics + 10 V = MMA
+ 0,5 – 3,5 V =MIG/MAG-process and MIG/MAG-dynamics setting
Signals in the control cable between the power source and the wire feeder unit:
Voltages in the E-line of control cable between the power source and the wire feeder:
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.
Power source size Arc on-info
13

Voltages in the H-line of the control cable between the power source and the wire feeder:
On MMA the wire feeder unit starts the power stage and develops an analog set value voltage of
0-10 V.
Minimi Maksimi
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.
Start Minimum Maximum Stop
Post-current time minimum = 40 ms Post curren time medium = 340 ms Post current time maximum = 760 ms
14

Voltages in the I-line of the control cable between the power source and the wire feeder:
On MMA the voltage of I-line is approx. + 10 V
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.
MIG/MAG dynamics - 9 MIG/MAG dynamics 0
MIG/MAG dynamics + 9
15

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 speed minimum Wire feed speed 10 m/min Wire feed speed maximum
The wf-unit controls the feed motor speed by PWM-principle.
Wire feed motor control
16

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.
D
D
Gun connection open Gun start (MT-type guns)
Startti
PMT-gun connected PMT-gun start
D
DD
17

D
PMT-connected and RMT in position 1
D
PMT-connected and RMT in position 3
PMT-connected and RMT in position 5
D
PMT –gun start and RMT in position 5
D
18

Signals from Wf-unit´s connectors
Pin Signal Explanation
A - -
B 30 Vac Supply voltage (fuse 6,3 A slow)
C 30 Vac Supply voltage (fuse 6,3 A slow)
D - -
E + 10 V Remote controller voltage reference
F 0 V GND
G 0 - 10 V Wire feed speed setvalue
H 0 - 10 V Set value to powersource (current or voltage)
I Process selection + 6 - 10 V =MMA
0 – 5 V or open = MIG/MAG-process
Remote controller connector XW101
Motor gun connection XW101
Pin Signal Explanation
A 0 V GND
B + 10 V Motor gun adj. potentiometer voltage reference
C 0 - 10 V Wire feed speed setvalue
D + M Gun motor positive +
E 0 - 10 V Voltage set value
F Start 2 Start-switch connector 2
G Start 1 Start-switch connector 1
H - M Gun motor negative -
I - -
19

Cooling unit control
A001
A002
Connector Signal
X7/1 Coolingunit start (in startthepower source control cardA001
pulls down the voltage on connectorX7/1)
X7/2 Supply voltage to control card A002 electronics (+ 24 V)
X7/3 GND
X7/4 Stop, if coolant pressure is less than 1 bar or the coolant
temperature risesabove +60° C, then thecontrolcard A002
pulls down the voltage on connector X7/4, which shuts the
power source down.
(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
*
Adjusting the cooling unit pressure watch limit
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.
20