Secondary Choke L001 - Kemppi Kempact 253R Service Manual

Operating voltage for the wire feed motor is rectified to capacitors C3-C5
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3.1.16. Secondary choke L001

The secondary choke L001 reduces ripple content of the secondary current
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3.1.17. Output RFI filter C001, C002
Capacitors C001 and C002 connected to the dowel screws (+ and -) reduce radio frequency interference
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3.1.18. Output terminal X004
Dix connector X004
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3.1.19. Euro connector X005
3.2. Main circuit diagram 181-, 251-models
181 and 251 machines have many common technical details with 253 and 323 machines. They have e.g. the same
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A001, P001, P002 and Z002 cards. Main differences to 253 and 323 machines are described here
3.2.1. PFC Choke L002
181 and 251 machines include PFC (Power Factor Correction) circuit. This is implemented using boost topology. The Boost to-
pology has choke in the input side of the converter. In Kempact 181 and 251 this choke is located on the front side of the com-
ponent frame from where it is wired into the component frame
3.2.2. PFC circuit auxiliary transformer T003
PFC circuit auxiliary power is generated using small toroidal transformer located inside the component frame
3.2.3. Main circuit card Z001
3.2.3.1. EMC Filter
Capacitors C7, C10, C15, C16 and inductor T6 form an EMC filter. The purpose C17 and R18 is to dampen common
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mode transients coming from mains
3.2.3.2. Inrush current limiting
PTC resistors R16 and R17 limit inrush current when the power source is switched on. PTCs are bypassed with relays
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K1 and K2 after DC link capacitors have been charged. Relays K1 and K2 are controlled by the microcontroller
3.2.3.3. IGBT driver
IGBT driver consists of gate transformers T2 and T3 and surrounding components
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3.2.3.4. Current transformer T1
Current transformer T1 is monitoring primary current and stops power stage operation if current is raising too high
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3.2.3.5. Main circuit
The main circuit consists of boost type PFC circuit followed by H-bridge type converter.
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Both parts of the main circuit are implemented using the same 600V, 75A six pack IGBT module
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One leg of the IGBT module is used for the Boost PFC circuit. Lower IGBT is used as the Boost power switch and the
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anti-parallel diode of the upper IGBT as the boost diode
The switching frequency of the boost circuit is ca. 15 kHz. The boost circuit raises DC link voltage to ca. 370V. Boost
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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
SERVICE MANUAL
KEMPACT RA_V_1.2
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