Kemppi Kempact Pulse 3000 User manual

Service manual
Ver. 1.3.2

Contents
Technical data…………………………………………… 3
Switches and connectors………....………………………4
Panel…...................………………………………………. 4, 5
Synergic curves….......…………………………………... 5
SETUP…………………………………………………… 6
Error codes……………………………...……………….. 6
Main circuit……………………………………………… 7
Main circuit diagram ………………………………...… 8
Troubleshooting diagram ………………………………. 9
Main circuit diagram Z001
Functions / connectors…………………………. 10
Layout……………………...…………………... 11, 12
Main transformer T001 primary voltage………. 11,12
Secondary diode card Z002
Functions / connectors ...………………………. 13
Layout………………………………………….. 13, 14
Voltage after the secondary diode card Z002 …. 14, 15
Control card A001
Functions / connectors ………………………….16, 17
Layout………………………………………….. 17
IGBT gate pulses…..……………………………18
Control card A002
Functions / connectors ………………………….19
Layout………………………………………….. 19
Wf- speed min and max adjustments…………... 20
Panel
Panel testing....................………………………. 21
Wf-motor current measuring...............………….21
Layout………………………………………….. 21
Structure….......………………………………………….. 22
IGBT testing …………………………………………….. 23
IGBT replacing…………………….......………………... 24
Notes……………………………………………................ 25
2

technical data
Supply voltage 3400 V
15% , 50/60 Hz
Loadability
(connection power)
40% ED 250 A / 26,5 V (12 kVA)
60% ED 207 A / 24 V (10 kVA)
100% ED 160 A / 22 V (7,5 kVA)
Supply cable(fuse) 4 x 1,5 mm22,5 m (16 A slow)
Welding voltage adj. range 8 - 30 V
Wf-speed adj. range 1 - 18 m/min
Power factor 0,69
Efficiency 0,84
Filler wires
Fe, Ss
FCW
Al
CuSi
0,6…1,0 mm
0,9…1,2 mm
0,9…1,2 mm
0,8…1,0 mm
Wire spool diameter (weight) 300 mm (15 kg)
Dimension(weight) L580 x W280 x H440 (22 kg)
OCV Approx. 57 V
3

Switches and connectors
Optical tachometer
Wf-motor
Pressure adjustment screw
Feed rolls
Gear wheel (18…24 m/min)
EURO-connector
Plus ( + )
Minus ( - )
Return current connector
Euro-connector
On/off-signal lamp
Overheat protection sign Net voltage over / undervoltage sign
2T/4T-tmethod selection
Setup (long press)
Aux. functions selection:
Crater fill
Hot Start
Spot timer Memory channels (100)
Process selection:
Double pulse
Pulse-MIG
1-MIG
Dynamics Gas test
Local / remote control
Wire inch
Plate thickness-/current
display selection
Adjustable parameter selection
Wf-speed
Voltage
Arc length
Chosen parameter adjustment
Panel
4

Panel
Selecto (5-channels)
Synergic curve number
Jumper number (Setup)
Synergic curve selection
Wf-speed
Voltage
Synergic curve material group
Jumper name (Setup)
Extra info of
synergic curve:
Material group
Wire diameter
Material type number
Gas type
Last welding value
Plate thickness -/
welding current display
Selected parameter
s value display
Synergic curves
5
1-MIG Pulse-MIG Program Material Gas
X 00 All All All
SS-group
X
X
X
X
S1
S2
0,8
0,9
SS 308 / 316 Ar + 2% C02
SS 308 / 316 Ar + 2% C02
Al-group
X X A1 1,0 AlMg 5 / AlMg 4,5Mn Argon
X X A2
1,0
AlMg 5 / AlMg 4,5Mn Argon
X X A6
1,2
AlSi 5 / AlSi 12 Argon
X X
C1
1,2 AlSi 5 / AlSi 12 Argon
Cu-group
X X
A7
0,8 CuSi 3 Argon
X X C3 1,0 CuSi 3 Argon
Fe-group
X
X
X
X
X
X
X
F1
F3
F5
F7
FA
0,8
1,0
0,8
1,0
1,0
Fe
Fe
Fe
Fe
Metal core wire
Ar + 25% C02
Ar + 25% C02
Ar + 25% C02
C02
C02
Normal-MIG 01 All All All
X X S3 1,0 SS 308 / 316 Ar + 2% C02
X X F2 0,9 Fe Ar + 25% C02

SETUP-functions
Error codes
Err 3 Net overvoltage
Err 4 Power source overheated
Err 5 Cooling unit has stopped welding
Err 6 Power source output voltage is has risen > 80 Vdc
Err 153 PMT-gun overheated or RMT 10 installed and PMT-gun in FU-position. In some cases this error may
be presented if one of the main supply voltage phases are missing.
Err 154 Wf-motor overload (current > 4,5 A/ 5 s.)
6
Parameter selection Parameter adjustment
10 s.
The SETUP is entered by pressing the setup-button for 10 seconds.
Adjustable parameter
Post gas time
Pre gas time
Hot Start level
2T Hot Start duration
Crater fill end level
Crater fill time (angle)
Creep start starting level
Creep start time (angle)
Doublepulse freq.
Double pulse Wf-speed amplitude
Ignition pulse
Pulse top current
Post current time
Arc length adj. range
Calibration
Maximum wf-speed
Liquid cooled gun PTC
Gun controller automatic detection
Display recovery delay
Number Display
Syn
Adj. range Quantity
1
2
11
12
14
15
17
18
21
22
31
33
35
41
42
51
53
54
81
99Factory settings recall
PoG
PrG
Hot
H2t
CFL
CFS
CSL
CSS
dFr
DA
StP
PuC
PoC
ALr
CAl
FS
Gun
GrE
dIS
FAC
Factory setting
Syn
30
2.0
30
1
Syn
0
Syn
Syn
0
0
Syn
0
0
18
On
On
5.0
OFF
0.0…9.9
0.0…9.9
-50…+75
0.1…9.9
10…90
1…20
10…90
0.1…5
0.0…8.0
0.0…3.0
-9…0…+9
-10…+15
0.0…10
-50…+75
1.0
18 tai 25
On/Off
On/Off
1.0…20
Off/Pan/All
s
s
%
s
%
s/10m/min
%
Hz
s/10m/min
m/min
%
s
%
V/100A
m/min
s
Err 253 Wrong welding process

+ t
L2
X27
X24
X30
+ t
X11 X10
X9
X18
C8
C10 C13
C9 C11 C12
5
6
7
1 2
3 4
V2
C6
C7
R13
X19 X20
L1
C4C3
R12R11
C2C1
R10R9
X2
G3
X8
G1
X3
G4
X6
G2
X1
E3
X7
E1
X21
X22
X4
E4
X5
E2
V1
X23
R5
Main circuit
Primary circuit.
Secondary circuit.
U
C2 R6
V1
V2
V3
V4
V5
R4
R3
V6
V7
V8
V9
V10
C1 R5
X1
X2
X3 X4
R1 R2
X5 X6 X7
U
7

Main circuit diagram
8

General
The machine may be repaired only by an authorized and licensed technician or workshop!
First do a visual check to find the possible loose connectors, broken wires or signs of overheating
Troubleshooting diagram
PROBLEM POSSIBLE CAUSE REMEDY
Power source doesn´t start Net fuses or supply cable. Check the net fuses and supply cable
condition.
Power source can´t provide full
power.
Net fuses or supply cable.
Main transformer T001 or
secondary siode card Z002.
Check the net fuses and supply cable
condition.
Check the main transformer T001´s
ferrites and secondary diode card
diodes.
9

Main circuit card Z001 functions and connectors
Main circuit card Z001 includes the following operational blocks:
•Overvoltage protection
•EMI-filter
•Primary rectifier
•DC-link charging
•DC-voltage filtering
•Full-bridge IGBT-module
Connectors
X1…X8 IGBT gates and emitters
X9 Fan M002
X10 and X11 Aux. transformer T002
X12, X14 and X17 Net voltage 400 Vac
X13, X15 and X16 Main switch S001
X18 Protective earth
X19 and X20 Charge relay
X21 and X22 Main transformer T001
X23 Intermediate circuit DC-voltage
X24, X27 and 30 Main switch S001
Main circuit card Z001 layout X1
X2
X3
X4
X5
X6
X7
X8
X9
X10
X11
L1
L2
L3
X18
X20
X19
X30
X24
X27
X23
X22
X21
10

Main circuit card Z001 layout
Smoothing capacitors
4 x 470 F / 450 V
Full-bridge IGBT
4 x 75 A / 1200 V
Primary rectifier
50 A / 1600 V Varistors
3 x 550 V
DC-link charging resistor and relay
Main switch
EMI-filter
Main transformer T001 primary voltage
a
Main transformer T001
transformation ratio 1:10
Wire feeding power supply
11

Main transformer T001 primary voltage with values 50 A/16,5 V (Synergic curve 00), meas. point a.
a
Main transformer T001 primary voltage
Main transformer T001 primary voltage with values 250 A/26,5 V (Synergic curve 00), meas. point a.
a
12

Secondary diode card Z002 functions / connectors
The secondary diode card Z002 has these operational blocks:
•Secondary rectifying
•Machine size coding
•Overvoltage protections
•Dampening circuits
Connectors
X1 and X2 Main transformer secondary
X3 and X4 Euro-connector
X5…X7 Machine size coding
Secondary diode card Z002 layout
X5
X6
X7
X2
X1 X3
X4
13

Secondary diode card Z002 layout
Fast diode 10 x 60 A / 400 V
Varistor 2 x 175 V
Voltage after the secondary diode card Z002
b
14

Voltage after the secondary diode card Z002
b
Voltage after the secondary diode card with values 50 A/16,5 V (Synergic curve 00), meas. point b.
c
Voltage after the secondary diode card with values 250 A/26,5 V (Synergic curve 00), meas. point b.
b
15

Control card A001 functions / connectors
The control card A001 has these operational blocks:
•RENESAS M16C26-microcontroller
•Panel connection
•Service bus (programming)
•Aux. voltages developement / - monitoring
•Power stage on/off-control
•Power stage PWM-control
•Primary current measuring
•Secondary current measuring
•Secondary voltage measuring
•Dynamics
•Ignition pulse
•Post Current
•Overheat protection
•Net overvoltage watch
•DC-link charging control
•Welding gun connection
•Wire feed control
•Solenoid valve control
Connectors
X1/1 CNVss
X1/2 Empty
X1/3 Empty
X1/4 Reset
X1/5 Empty
X1/6 Panelbus, (transmit)
X1/7 Empty
X1/8 Empty
X1/9 Serial bus 1, transmit
X1/10 Serial bus 1, receive
X1/11 Empty
X1/12 Empty
X1/13 Empty
X1/14 Panel bus, (receive)
X1/15 + 5 V
X1/16 GND
X2/1 CNVss
X2/2 Empty
X2/3 GND
X2/4 Empty
X2/5 Empty
X2/6 Reset
X2/7 + 5 V
X2/8 Empty
X2/9 Serial bus 1, transmit
X2/10 Serial bus 1, receive
Connectors
X3/1,2 Charging relay
X4/1,2 PTC, sec. Diodes
X5/1,2 PTC, sec. Choke
X6/1,2 PTC, IGBT
X7/1,2 Aux. transformer secondary
X8 Empty
X9 Protective earth
X10/1 E1, IGBT
X10/2 Empty
X10/3 E2, IGBT
X10/4 G1, IGBT
X10/5 Empty
X10/6 G2, IGBT
X11 Intermediate circuit DC-voltage
X12/1 E4, IGBT
X12/2 Empty
X12/3 E3, IGBT
X12/4 G4, IGBT
X12/5 Empty
X12/6 G3, IGBT
X13/1,2 Shunt
X14/1 Sec. Voltage
X14/2 GND
X14/3 + 5 V
X14/4 WF-motor tachometer
X14/5,6 Current transformer
16

Connectors
X14/7-9 Machine size coding
X14/10 GND
X14/11 Empty
X14/12 Empty
X15/1 + 24 V / Solenoid valve
X15/2 Empty
X15/3 Empty
X15/4 Solenoid valve
X15/5,6 Gun switch
X16/1 + 15 V
X16/2 GND
X16/3 GND
X16/4 Empty
X16/5 Empty
X16/6 Wire feed on/off-control
X16/7 Cooling unit alarm
X16/8 Wf-motor current measuring
X16/9 + 24 V
X16/10 Cooling unit on/off control
X16/11 Wf-motor speed set value
X16/12 Empty
Control card A001 connectors
Control card A001 layout
LEDs:
H1 + 5V
H2 + 15V
H3…H6 Gate pulses
X13
X11
H6
X12 H5 H4 X10 H3 X5 X6 X5 X4 X3
H1
X1
X16
X2
H2
X15X14
X8
X7
17

IGBT gate pulses
Gate pulse in idling, measuring point c.
c
Z001
c
A001
18

Control card A002 functions / connections
Control card A002 has these operational blocks:
•Wf-motor control (PWM)
•Power supply filtering
•Overvoltage protection
Connectors
X1/1 + 15 V
X1/2 Wf-motor plus
X1/3 Main transformer aux. coil
X1/4 + 5 Vref2
X1/5 Wf-speed set value
X1/6 Main transformer aux. coil
X1/7 GND
X1/8 Wf-motor current
X1/9 Main transformer aux. coil
X1/10 Wire feed on/off control
X1/11 Wf-motor minus
X1/12 Main transformer aux. coil
19
Control card A002 layout
X1
R32 (Min) R21 (Max)
F1 (6,3 AT)

Wire feed speed minimum and maximum adjustments
X1
R32 (Min) R21 (Max)
F1 (6,3 AT)
After replacing control card A002 or feed motor M001, the wf-speed has to be checked and
adjusted as follows:
1. From panel, choose synergic curve 00
2. Connect the power source to a load bank
3. Set wf-speed to 18 m/min
4. Check the actual speed and if necessary, adjust by trimmer R21
5. From panel, set the speed to 1 m/min
6. Check the actual speed and if necessary, adjust it by trimmer R32
7. Re-check maximum and minimum
If not using load bank, you have to check creep start level because of without short circuit creep
start won’t upslope to the welding value:
1. From panel, choose synergic curve 00
2. Set wf-speed to 18 m/min
3. Enter the setup and adjust parameter CSL value to ‘syn’
4. When ‘syn’ is plinking you can see the creep start value (in case of welding value 18m/min,
the actual value will be 12m/m)
5. Measure fed wire length and if necessary, adjust by trimmer R21
6. From panel, set the speed to 1 m/min (also creep start value will be 1m/min)
7. Measure fed wire and if necessary, adjust it by trimmer R32
8. Re-check maximum and minimum
20