Kemppi KEMPACT PULSE 3000 Service Manual
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Kemppi KEMPACT PULSE 3000 Service Manual

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Service manual
Ver. 1.3.2

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Summary of Contents for Kemppi KEMPACT PULSE 3000

  • Page 1 Service manual Ver. 1.3.2...

  • Page 2: Table Of Contents

    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……….

  • Page 3: Technical Data

    technical data 3 400 V 15% , 50/60 Hz Supply voltage Loadability 40% ED 250 A / 26,5 V (12 kVA) (connection power) 60% ED 207 A / 24 V (10 kVA) 100% ED 160 A / 22 V (7,5 kVA) Supply cable(fuse) 4 x 1,5 mm 2,5 m (16 A slow)

  • Page 4: Switches And Connectors

    Switches and connectors Optical tachometer Wf-motor Pressure adjustment screw Feed rolls Gear wheel (18…24 m/min) EURO-connector Minus ( - ) Return current connector Plus ( + ) Euro-connector Panel Overheat protection sign Net voltage over / undervoltage sign On/off-signal lamp Adjustable parameter selection Wf-speed 2T/4T-tmethod selection...

  • Page 5: Synergic Curves

    Panel Plate thickness -/ Wf-speed welding current display Voltage Synergic curve number Selected parameter s value display Synergic curve material group Jumper number (Setup) Jumper name (Setup) Last welding value Selecto (5-channels) Extra info of Synergic curve selection synergic curve: Material group Wire diameter Material type number...

  • Page 6: Setup

    SETUP-functions The SETUP is entered by pressing the setup-button for 10 seconds. 10 s. Parameter selection Parameter adjustment Adjustable parameter Number Display Factory setting Adj. range Quantity Post gas time 0.0…9.9 Pre gas time 0.0…9.9 Hot Start level -50…+75 2T Hot Start duration 0.1…9.9 Crater fill end level 10…90...

  • Page 7: Main Circuit

    Main circuit Primary circuit. Secondary circuit.

  • Page 8: Main Circuit Diagram

    Main circuit diagram...

  • Page 9: Troubleshooting Diagram

    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.

  • Page 10: Functions / Connectors

    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 Fan M002 X10 and X11 Aux.

  • Page 11: Layout

    Main circuit card Z001 layout DC-link charging resistor and relay Smoothing capacitors 4 x 470 F / 450 V Main switch EMI-filter Full-bridge IGBT Primary rectifier 4 x 75 A / 1200 V 50 A / 1600 V Varistors 3 x 550 V Main transformer T001 primary voltage Wire feeding power supply Main transformer T001...
  • Page 12 Main transformer T001 primary voltage Main transformer T001 primary voltage with values 50 A/16,5 V (Synergic curve 00), meas. point a. Main transformer T001 primary voltage with values 250 A/26,5 V (Synergic curve 00), meas. point a.

  • Page 13: Functions / Connectors

    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...

  • Page 14: Voltage After The Secondary Diode Card Z002

    Secondary diode card Z002 layout Varistor 2 x 175 V Fast diode 10 x 60 A / 400 V Voltage after the secondary diode card Z002...
  • Page 15 Voltage after the secondary diode card Z002 Voltage after the secondary diode card with values 50 A/16,5 V (Synergic curve 00), meas. point b. Voltage after the secondary diode card with values 250 A/26,5 V (Synergic curve 00), meas. point b.

  • Page 16: Functions / Connectors

    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 •...
  • Page 17 Control card A001 connectors Connectors X14/7-9 Machine size coding X14/10 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 X16/3 X16/4 Empty X16/5 Empty X16/6 Wire feed on/off-control...

  • Page 18: Igbt Gate Pulses

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

  • Page 19: Functions / Connectors

    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...

  • Page 20: Wf- Speed Min And Max Adjustments

    Wire feed speed minimum and maximum adjustments F1 (6,3 AT) R32 (Min) R21 (Max) 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.

  • Page 21: Panel Testing

    Panel testing Panel program version Power source program version Panel switches, LEDs and displays can be tested. After turning the power source on (3 sec.) all LEDs and displays should be lighted and after pressing any of the buttons the program versions should be shown on the panel.

  • Page 22: Structure

    Structure A002 Control card P001 Panel Y001 Solenoid valve A001 Control card M002 S001 Main switch R001 Shunt L002 Z002 Z001 Sec. choke Secondary diode card Main circuit card...

  • Page 23: Igbt Testing

    IGBT testing IGBT-module can be tested in two phases with an IGBT tester as seen in picture below: C1/3 X2/G3 B1/4 X3/G4 X6/G2 C2E1/1 X8/G1 B2/6 E2/2 C1/3 B1/4 C2E1/1 B2/6 E2/2...

  • Page 24: Igbt Replacing

    IGBT replacement IGBT mounting onto the heat sink The installation surfaces must be clean, even very small particles (0,050mm) between the surfaces increase the gap between heat sink and module, causing module overheating and possibly destruction. Heat transfer paste is spread as an even layer about 0,1 mm thick, onto the modules base plate. The module is immediately attached to the heat sink, in order to avoid any dirt to get between the components.

  • Page 25: Notes

    Notes...

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