Kemppi FASTMIG X 450 Service Manual
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Summary of Contents for Kemppi FASTMIG X 450
- Page 1 20.6.2013 SERVICE MANUAL FASTMIG X FASTMIG X 450 MXP37 PIPE MXP 38 Kemppi Oy...
- Page 2 SERVICE MANUAL KEMPACT RA Kemppi Oy...
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Page 3: Table Of Contents
SERVICE MANUAL 1 (37) FASTMIG X CONTENTS FASTMIG X 450 ..................................... 4 TECHNICAL DATA ..................................... 4 1. MAIN CIRCUIT DIAGRAM ..................................5 1.1. Forced cooling components ................................5 1.2. Control side devices ..................................5 1.3. Overheat protection PTCs (Rg101, Rt101, Rg201) .......................... 5 2. - Page 4 4. LOW VOLTAGE TEST ..................................... 32 5. MAIN COMPONENTS INSTALLATION ..............................32 5.1. Main circuit card Z001 .................................. 32 5.2. Secondary rectifier card Z003 ..............................32 5.2. Cut off card Z004 ..................................32 6. ERR0R CODES ....................................33 Kemppi OY...
- Page 5 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 6: Fastmig X 450
Ssc greater than or equal to 5.5 MVA. FastMig X 450 is an inverter power source. Topology of the main power circuit is full bridge. The full bridge topology requires four power switches which are implemented using IGBT module. Switching frequency of the power switches is 20 kHz. Power source is controlled by microcontroller with the help of FPGA. -
Page 7: Main Circuit Diagram
(A001, A002 and A003). 1.3. Overheat protection PTCs (Rg101, Rt101, Rg201) PTC resistors connected to the primary heat-sinking profile (Rg101), main transformer (Rt101) and secondary heat- • sinking profile (Rg201) provides overheat protection for the power source. Kemppi OY... -
Page 8: Main Circuit Card Z001
Topology of the power stage is traditional full bridge. The full bridge topology requires four power switches which are • implemented using IGBT module (V1). Switching frequency of the power switches is 20 kHz. IGBT size is 4 x 150 A 1200 V • Kemppi OY... -
Page 9: Connectors
Main transformer X8-X15 IGBT gates and emitters Primary choke Primary choke DC-link voltage (+) DC-link voltage (+) DC-link voltage (-) DC-link voltage (-) Chassis ground DC-link voltage (+) Current transformer secondary Current transformer secondary Auxiliary transformer Auxiliary transformer Kemppi OY... -
Page 10: Dc-Link Capacitor Card Z002
The purpose of the DC-link capacitors (C1-C8) is to provide energy storage and low impedance voltage source for the • power stage. Resistors (R1-R4) discharge DC-link capacitors when power source is switched off. 3.2. Connectors Connector Description DC-link voltage (+) DC-link voltage (+) DC-link voltage (-) DC-link voltage (-) Kemppi OY... -
Page 11: Secondary Rectifier Card Z003
Varistors (R1, R3, R5, R7) are for TIG ignition spark protection • 4.1. Connectors Connector Description Main transformer Main transformer Main transformer Main transformer Not in use Not in use Not in use Not in use Main transformer Kemppi OY... -
Page 12: Secondary Cut Off Card Z004
The whole secondary current goes through secondary profile between rectifier card Z003 and cut-off card Z004 • 5.1. Connectors Connector Description X1:1 Optical coupler anode X1:2 Optical coupler cathode X1:3 Not in use X1:4 +24Vdc X1:5 FET FAILURE signal X1:6 X5-X8 Secondary choke Kemppi OY... -
Page 13: Gate Driver Card A001
Remote control device is isolated from the power source LED H7 indicates that remote control unit is connected when it is lit • 6.4. Voltage monitoring Comparator N6 monitors 15V supply voltage and DC-link overvoltage and shuts down the power stage if necessary • Kemppi OY... -
Page 14: Leds
Remote control analog input X9:9 Remote control analog input X9:10 System bus GND X9:11 System bus GND X9:12 System bus GND Chassis ground X13:1 PTC, primary heat sink profile X13:2 PTC, primary heat sink profile X14:1 PTC, main transformer Kemppi OY... - Page 15 Spare supply voltage +24V X16:12 Auxiliary voltage ground X17:1 Cooling unit, supply voltage +24V X17:2 Cooling unit, error signal X17:3 Cooling unit, GND X17:4 Cooling unit, analog input X17:5 Cooling unit, analog input X17:6 Cooling unit, on/off signal Chassis ground Kemppi OY...
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Page 16: Processor Card A002
FPGA is used to implement peak current-mode control to directly control (peak) primary current. FPGA adjusts prima- • ry peak current so that secondary current is same as reference current given by microcontroller FPGA is configured every time when the power source starts up • Kemppi OY... -
Page 17: Cut-Off Card Connection
State of the microcontroller State of the microcontroller State of the microcontroller FPGA’s configuration Auxiliary voltages 15 V Auxiliary voltages 5,3 V Auxiliary voltages 1,2 V Auxiliary voltages 5 V Auxiliary voltages 2,5 V Auxiliary voltages 3,3 V Kemppi OY... -
Page 18: Connectors
Current transformer (ac) X9:5 Machine size jumper J1 X9:6 Machine size jumper J2 X11:1 Not connected X11:2 Differential secondary voltage + X11:3 Shunt (+) X11:4 Secondary voltage (+) X11:5 Differential secondary voltage - X11:6 GND, Shunt (-) RTC battery Kemppi OY... -
Page 19: System Card A003
17 (37) FASTMIG X 8. SYSTEM CARD A003 System card in FastMig X 450 is to make possible MMA welding without separate wire feed unit • System card is connected to power source via CAN bus with connector X1 •... -
Page 20: Setup Panel Card P001
20V secondary supplies the control card A001 circuitry and the fans M001 and M002 • 38V secondary voltage is rectified with auxiliary rectifier (G003) to 50V dc –voltage • 10.6. Auxiliary rectifier bridge G003 50V dc voltage supplies the serial communication bus and devices that are connected to it • Kemppi OY... -
Page 21: Fan Control
MMA and Service-mode fan1 is always on. Fan2 starts 7s delay from the welding start. Power source calcu- lates time integral of the welding current. This integral defines post run time of the fan2. Minimum post run time is 20s maximum 5min Fans are on always when power source over temperature error is on • Kemppi OY... -
Page 22: Mxp 37 Pipe
Wire feeder’s spool space can be heated if wire feeder is operating in cold or wet conditions. Maximum power for • heating element is 50W (50V, 1A). There is no control circuit for heating element so the heating element is always on when wire feeder’s supply voltage is connected Kemppi OY... -
Page 23: Gas Guard S003 (Optional)
• ing” parameters for the complete package, this information is transferred between panels and devices, via a CAN bus network, with KeBus (Kemppi bus) and KeFS (Kemppi file system) protocols 1.8. Panel card P001 Panel is connected to the A001 card via a ribbon cable. -
Page 24: Motor Control Card A001
Flyback controller N2 is used to regulate +9V (actual value is 10,6V) voltage from +50V. Step down regulator N14 is • used to regulate +5V from +9V. Low dropout regulator N1 regulates +3.3V 2.2. Leds Description Data line Aux. voltage + 5 Vdc Aux. voltage + 9 Vdc Aux. voltage + 3,3 Vdc Kemppi OY... -
Page 25: Connectors
Spool space heater (-) X14:1 External start X14:2 X14:3 ARC ON signal output X14:4 Remote control WFS X14:5 Remote control U X14:6 +5V, Remote control X15:1 Motor 2+ X15:2 Motor 1- X15:3 Motor 1+ X15:4 Motor 2- X15:5 System bus +50V Kemppi OY... -
Page 26: Memory Card A003
Not connected X19:1 Gas guard (+) X19:2 Gas guard (-) 3. MEMORY CARD A003 Memory card is connected to motor control card A001 • Flash memory is programmed in Kemppi production line • 3.1. Connectors Connector Description X1:1 X1:2 X1:3... -
Page 27: Mxp 38
- different motor control card A001 because wire feeder has voltage sensing connector X16 on card - wire feeder has own voltage sensing cable connectors (front and back) for measuring cable - MXP 38 include own panel unit XF38 Kemppi OY... -
Page 28: Operational Measurings And Tests
FASTMIG X OPERATIONAL MEASURINGS AND TESTS NOTE! Main supply voltage must not be connected when making measuring operations. The component frame has to be uninstalled so that main components conditions can be measured. 1. MAIN CIRCUIT CARD Z001 Kemppi OY... -
Page 29: Primary Rectifier V5
Measurings: Positive test lead Negative test lead Result X1, X2, X3 (one at time) 0,3-0,7VDC X1, X2, X3 (one at time) no value X1, X2, X3 (one at time) 0,3-0,7VDC X1, X2, X3 (one at time) no value Kemppi OY... -
Page 30: Igbt Module V6
When measuring IGBT unit diodes you must disconnect other end (X7) of main transformer • DC link (+) DC link (-) Measurings: Positive test lead Negative test lead Result 0,3-0,7VDC no value 0,3-0,7VDC no value 0,3-0,7VDC no value 0,3-0,7VDC no value Kemppi OY... - Page 31 FASTMIG X IGBT MODULE TEST: Kemppi IGBT-tester is simple way to be sure that module is working. Tester simulates DC link voltage and • gate pulses and measures output voltage. Tester can trigger two IGBTs at the same time (one for positive and one for negative) so it have to be connected two different ways to test the whole IGBT module.
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Page 32: Secondary Rectifier Card Z003
Remember to test diodes both ways: forward bias and reverse bias • Measurings: Positive test lead Negative test lead Result Z003, heatsink 0,3-0,7VDC Z003, heatsink 0,3-0,7VDC Z003, heatsink 0,3-0,7VDC Z003, heatsink 0,3-0,7VDC Z003, heatsink no value Z003, heatsink no value Z003, heatsink no value Z003, heatsink no value Kemppi OY... -
Page 33: Cut-Off Card Z004
Mosfet can be measured with diode function. There is threshold value across the component between drain and • source Component must release from card that measuring results are reliable • Measurings: MOSFET Positive test lead Negative test lead Result S to D forward biased 0,3-0,7VDC D to S reverse biased No value Kemppi OY... -
Page 34: Low Voltage Test
After replacing components it’s recommended to start machine with low voltage test • Measuring: Input 20VAC (Kemppi Multipower) to aux. transformers connector X2 pins 1-2 or 2-3 • o voltage goes thought secondary winding to primary side as 400VAC o voltage goes also to another secondary coil as 38VAC o machine starts up and DC link voltage can be measured Z002 X1 and X3 5. -
Page 35: Err0R Codes
Licence code wrong/missing Wrong licence code, activate right code WF rollers, rear sliping Check rollers and mechanical parts WF rollers, front sliping Check rollers and mechanical parts Welding not allowed Can bus not respond the command or bus occupied Kemppi OY... - Page 36 Error while reading or writing to Machine can not write to feeder memory card, check the cables memory and connections, possibly broken control/memory card Panel can not connect to the CAN Check the flat cables. Check the panels Kemppi OY...