Kemppi Kempact 253R Service Manual
Kempact ra series
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Also See for Kempact 253R:
- Operating manual (42 pages) ,
- Quick manual (13 pages) ,
- Quick manual (13 pages)
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Summary of Contents for Kemppi Kempact 253R
- Page 1 SERVICE MANUAL KEMPACT RA 181A 251R/251A 253R/253A 323R/323A 253MV/323MV Kemppi Oy...
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Page 2: Table Of Contents
3.4.2.1. EMC filter ..................................18 3.4.2.2. Inrush current limiting ..............................18 3.4.2.3. IGBT driver ................................... 18 3.4.2.4. Current transformer T1 ............................... 18 3.4.2.5. Main circuit .................................. 18 3.4.2.6. PFC Boost control circuitry ............................18 4. MAIN CIRCUIT CARD Z001 ..................................19 Kemppi Oy... - Page 3 Digital multimeters may give different values depending the specifications they have. For example diode measuring values may vary between the multimeters models. Special attention must be considered while working with the internal parts. The device may be repaired only by a person legally authorized to perform electrical work. Kemppi Oy...
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Page 4: Service Manual
SERVICE MANUAL 3 (40) KEMPACT RA_V_1.2 1. PARTS OF MACHINE Kempact RA (253, 323) Kemppi Oy... - Page 5 SERVICE MANUAL 4 (40) KEMPACT RA_V_1.2 Kempact RA (253, 323) NOTE ! spareparts@kemppi.com Spare part info available from: (email). Kemppi Oy...
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Page 6: Technical Information
EMC class Degree of protection IP23S IP23S Operating temperature range -20…+40 °C -20…+40 °C Storage temperature range -40…+60 °C -40…+60 °C Standards IEC 60974-1 IEC 60974-1 IEC 60974-5 IEC 60974-5 IEC 60974-10 IEC 60974-10 IEC 61000-3-12 IEC 61000-3-12 Kemppi Oy... - Page 7 SERVICE MANUAL 6 (40) KEMPACT RA_V_1.2 Kempact 253R, 253A Kempact 323R, 323A Connection voltage 50/60Hz 400V+- 15% 3~ 50/60Hz 400V +- 15% 3~ Rated power at max. current 40% ED I1max (250A) 8.34kVA/7.73kW 35% ED I1max (320A) 12kVA/11.3kW Supply current 40% ED I1max (250A) 11.9A...
- Page 8 623x579x1070 mm LxWxH 623x579x1070 mm Not including gun and Not including gun and Weight gables 44 kg gables 44 kg Temperature class F(155 C) F(155 C) EMC class Degree of protection IP23S IP23S Operating temperature -20…+40 °C -20…+40 °C Kemppi Oy...
- Page 9 SERVICE MANUAL 8 (40) KEMPACT RA_V_1.2 range Storage temperature range -40…+60 °C -40…+60 °C Standards IEC 60974-1 IEC 60974-1 IEC 60974-5 IEC 60974-5 IEC 60974-10 IEC 60974-10 IEC 61000-3-12 IEC 61000-3-12 Kemppi Oy...
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Page 10: Main Circuit Diagrams
SERVICE MANUAL 9 (40) KEMPACT RA_V_1.2 2.2. Main circuit diagrams Kemppi Oy... - Page 11 SERVICE MANUAL 10 (40) KEMPACT RA_V_1.2 Kemppi Oy...
- Page 12 SERVICE MANUAL 11 (40) KEMPACT RA_V_1.2 * Please refer to Kemppi Channel for the latest version of main circuit drawings ! Kemppi Oy...
- Page 13 Wire feed motor M003 • Brights led card P002 • Panel card P001 • Main circuit card Z001 • Secondary rectifier card Z002 • Secondary choke L001 • Output RFI filters C001 and C002 • Euro connector X005 • Kemppi Oy...
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Page 14: Main Components
The microcontroller also regulates wire feed speed by setting motor current reference and measuring EMF of the • motor 3.1.8.3. Motor control Wire feed motor control is based on EMF (electro magnetic force) measurement principle • Kemppi Oy... -
Page 15: Fans M001, M002
Capacitors C1 and C2 and resistors R3 and R4 form a snubber circuit. The snubber circuit reduces the voltage stress of • the diodes caused by the reverse recovery current snap off Varistors R1 and R2 are for TIG ignition spark protection • Kemppi Oy... -
Page 16: Secondary Choke L001
The switching frequency of the boost circuit is ca. 15 kHz. The boost circuit raises DC link voltage to ca. 370V. Boost • input current is measured using shunt resistors R58, R59, R65, R66. H – bridge is implemented using the other two legs of the IGBT module Kemppi Oy... -
Page 17: Pfc Boost Control Circuitry
When IGBT-transistors G1 and G4 conduct, there is a positive voltage U in main transformer T1 primary and when IGBT- transistors G2 and G3 conduct there is a negative voltage U in main transformer primary. Power is adjusted by changing the Kemppi Oy IGBT timings (PWM). - Page 18 SERVICE MANUAL 17 (40) KEMPACT RA_V_1.2 Kemppi Oy...
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Page 19: Main Circuit Diagram 253Mv-, 323Mv-Models
PFC control circuitry is located on the primary side. Auxliary transformer T003 supplies operating voltage for the PFC • control circuitry. The output voltage of the T003 is first rectified and then linear regulator is used to regulate auxiliary voltage to 15V. PFC control IC N1 regulates DC-link voltage to approximately 630V. Kemppi Oy... -
Page 20: Connectors
Main voltage connector Mains voltage Mains voltage connector Signal Chassis ground connector Signal Auxiliary transformer connection, auxliary transformer is protected with PTC resistors R63 and R64 PFC Auxiliary transformer connection, auxliary transformer is protected with PTC resistors R63 and R64 Kemppi Oy... - Page 21 Other end of the IGBT driver transformer primary X10:11 PFC ON/OFF N PFC on/off opto coupler diode negative end X10:12 Signal PFC choke connections PFC choke connections PFC choke connections PFC choke connections Signal DC-link voltage DC-link voltage Kemppi Oy...
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Page 22: Kempact 253, 323
Auxiliary transformer connection, auxliary transformer is protected with PTC resistors R16 and R17 Signal Main transformer connections (253 machine use two flat connectors, 323 use four) Main transformer connections (253 machine use two flat connectors, 323 use four) Kemppi Oy... - Page 23 IGBT Drive A Other end of the IGBT driver transformer primary X9:5 OV Opto N Over voltage optocoupler other end X9:6 Inrush Relay Other end of the inrush relay coil Signal Primary current transformer connector Signal DC-link voltage DC-link voltage Kemppi Oy...
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Page 24: Kempact 253Mv, 323Mv
X3, X22 Mains voltage Mains voltage connector Signal Chassis ground connection Signal Description Auxliary transformer connectors. Auxliary transformer is protected with PTC resistors R63 and R64. Auxliary transformer connectors. Auxliary transformer is protected with PTC resistors R63 and R64. Kemppi Oy... - Page 25 Over voltage optocoupler other end X18:4 IGBT Drive A Other end of the IGBT driver transformer primary X18:5 PFC ON/OFF N PFC on/off opto coupler diode positive end X18:6 OV Opto N Over voltage optocoupler other end Signal DC-link voltage DC-link voltage Kemppi Oy...
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Page 26: Secondary Rectifier Card Z002
SERVICE MANUAL 25 (40) KEMPACT RA_V_1.2 5. SECONDARY RECTIFIER CARD Z002 5.1. Connectors Signal Main transformer secondary Main transformer secondary Z002 card connection to secondary profile Z002 card connection to secondary profile Rectified +24V Polarity connector (-) Kemppi Oy... -
Page 27: Control Card A001
Signal Description X2:1 + 50 V Secondary voltage from secondary card X2:2 Ground X2:3 + 24 V +24V from the auxiliary transformer X2:4 Motor (+) Wire feed motor (+) X2:5 Motor (-) Wire feed motor (-) X2:6 Ground Kemppi Oy... - Page 28 IGBT driver transformer other end X6:5 PTC connection X6:6 Start A Gun switch connection Signal Connections to chassis ground Signal Used in development purposes, do not connect anything here Signal Maintenance use Signal Panel card P001 connection Signal Not in use Kemppi Oy...
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Page 29: Panel Card P001
Pulse potentiometer 2 channel A X1:11 Pot_2_B Pulse potentiometer 2 channel B X1:12 Ground X1:13 Pot_3_A Pulse potentiometer 3 channel A X1:14 Pot_3_B Pulse potentiometer 3 channel B X1:15 +5V supply voltage X1:16 +24V +24V supply voltage for the LCD backlight Kemppi Oy... -
Page 30: Kempact 181, 251
Result: 0,3…0,6 diodes Ok 4) Positive pole to rectifier pole (4, red), negative test pole to rectifier poles (1, black) one at the time Result: no value diodes Ok NOTE ! The measurement procedure is same for V24 and V25 rectifiers. Kemppi Oy... -
Page 31: Igbt Module V1
1) Positive test pole (1, red) to connector X16, negative test pole (1, black) to connectors X7, X8 and X14 one at time Result: 0,3…0,6 diodes Ok 2) Negative test pole (2, black) to connector X13, positive test pole (2, red) to connectors and X7, X8 and X14 one at time Result: 0,3…0,6 diodes Ok Kemppi Oy... -
Page 32: Kempact 253, 323
3) Negative test pole to DC-link (+), positive test pole L1, L2, L3 (one at the time) Result: 0,3…0,6 diodes Ok 4) Negative test pole to DC-link (-), positive test pole L1, L2, L3 (one at the time) Result: no value diodes Ok Kemppi Oy... -
Page 33: Igbt Module, V2
1) Positive test pole to connector X7 and X8 one at time, negative test pole to DC link (+) Result: 0,3…0,6 diodes Ok 2) Positive test pole to DC-link (-), negative test pole to X7 and X8 one at time Result: 0,3…0,6 diodes Ok Kemppi Oy... -
Page 34: Kempact 253Mv, 323Mv
3) Positive test pole to rectifier pole (2, red), negative test pole rectifier poles (2, black)one at the time Result: 0,3…0,6 diodes Ok 4) Negative test pole to rectifier pole (3, black), positive test pole to rectifier poles (2, red) one at the time Result: no value diodes Ok Kemppi Oy... -
Page 35: Igbt Module, V1
1) Negative test pole (1, black) to connector X19, positive test pole (1, red) to connectors X13, X14 and X17 one at time Result: 0,3…0,6 diodes Ok 2) Positive test pole (2, red) to connector X20, negative test pole (2, black) to connectors and X13, X14 and X17 one at time Result: 0,3…0,6 diodes Ok Kemppi Oy... - Page 36 1) Positive test pole to main transformer secondary (secondary card connectors X1 and X2 one at time), negative test pole to secondary profile Result: 0,3…0,6 diodes Ok 2) Positive test pole to secondary profile, negative test pole to main transformer secondary (secondary card connectors X1 and X2 one at time) Result: no value diodes Ok Kemppi Oy...
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Page 37: Ptc's, Overheat Protection
Primary rectifier V1 to heatsink 2 NM • IGBT unit to heatsink • First step 2 NM and wait a couple minutes Second step 3 NM Main circuit card Z001 to profile holder 0,7 NM • Primary unit to component frame 2 NM • Kemppi Oy... -
Page 38: Secondary Rectifier Card Z002
• Auxiliary transformer T002 to component frame 5 NM • Secondary choke L001 to component frame 2 NM • Secondary choke L001 other lead to secondary profile 5 NM and other lead to polarity screw 5 NM • Kemppi Oy... -
Page 39: Error Codes
-communication error between panel card -check flat cable/connectors between P001 and control card A001 panel- and control card Panel communication error -communication error between panel card -check flat cable/connectors between P001 and control card A001 panel- and control card Kemppi Oy...