Kemppi KEMPOMIG 3200 Service Manual
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Kemppi KEMPOMIG 3200 Service Manual

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Service manual
Ver. 1.0
400
FEED

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Summary of Contents for Kemppi KEMPOMIG 3200

  • Page 1 Service manual Ver. 1.0 FEED...

  • Page 2: Table Of Contents

    Contents General…………………………………………………….3 Technical data………………………………...…………...3 Switches and connectors………………………….………4, 5 Operation principle……………………...………………..5 IGBT-module control………...…………………………. 6, 7 Voltage after secondary diodes…………..…………..8, 9 Troubleshooting/diagram…………………...…………...10-12 Wire feeder´s error codes……………………….……….12 Signals between power source and wire feeder………...13-15 Solenoid valve control…………………………….………16 Wire feed motor control.………………………….……...16 Torch connection……….………………...……………….17, 18 Signals from Wf-unit´s connectors…...………………….19 Cooling unit control……………….……………………...20 Adjusting the cooling unit pressure watch limit.……..20...

  • Page 3: General

    General Kempomig-power sources are MIG/MAG and MMA –power sources designed for professional use. Kempomig-power sources are inverter power sources based on IGBTs controlled by PWM principle. The operating frequency is fixed on 18 kHz throughout the machine´s operating range. Kempomig-power source together with Feed-unit form a compilation, in which the Feed-unit controls all the operations.

  • Page 4: Switches And Connectors

    Switches and connectors 15 16 1 Process selection 14 MSD 1-meter unit 2 Local / remote control selection 15 Coolant overheat signal lamp 3 Wire feed speed-/ plate thickness display 16 Cooling unit test switch 4 Wire feed speed -/ power adjustment 17 Missing pressure signal lamp 5 Voltage -/arc length -/ current setting 18 Main switch S001...

  • Page 5: Operation Principle

    5 6 7 1 Synergic program selection 2 Crater fill on/off 3 Post current adjustment 40 ms…760 ms Operation principle Kempomig- power sources power stage is a traditional half-bridge, where the DC-link´s voltage is halved by load capacitors C2 and C3. IGBT transistors work as power switches. When both IGBTs are non-conductive, no power is transferred.

  • Page 6: Igbt-Module Control

    IGBT-module control A = Gate pulse (10 A / 20,4 V, MMA) B = Voltage over the lower IGBT (10 A / 20,4 V, MMA) Inverter frequency approx. 17 kHz A = Gate pulse (100 A / 24,0 V, MMA) B = Voltage over the lower IGBT (100 A / 24,0 V, MMA) Inverter frequency approx.
  • Page 7 IGBT-module control A = Gate pulse (320 A / 32,8 V, MMA) B = Voltage over the lower IGBT (320 A / 32,8 V, MMA) Inverter frequency approx. 17 kHz A = Gate pulse (400 A / 36,0 V, MMA) B = Voltage over the lower IGBT (400 A / 36,0 V, MMA) Inverter frequency approx.

  • Page 8: Voltage After Secondary Diodes

    Voltage after secondary diodes C = Voltage after the secondary diodes (10 A / 20,4 V, MMA) Frequency approx. 35 kHz C = Voltage after the secondary diodes (100 A / 24,0 V, MMA) Frequency approx. 35 kHz...
  • Page 9 Voltage after secondary diodes C = Voltage after secondary diodes (320 A / 32,8 V, MMA) Frequency approx. 35 kHz C = Voltage after secondary diodes (400 A / 36,0 V, MMA) Frequency approx. 35 kHz...

  • Page 10: Troubleshooting/Diagram

    Troubleshooting The device may be repaired only by a person legally authorized perform electric work! Always check the device visually first, to find possible damages like loose wires, breaks or signs of overheating. Also note the condition of the welding cables, welding gun and wire feed mechanism. Troubleshooting diagram DISTURBANCE POSSIBLE CAUSE...
  • Page 11 DISTURBANCE POSSIBLE CAUSE REMEDY Error code E08 is shown on the Faulty welding gun Check the welding gun condition panel display Faulty wf-unit control card Check the wf-unit´s zener diodes A001 V27 and V28 (24 V/5 W) on control card A001. If these diodes get damaged, there is an insulation problem in the welding gun between welding circuit and start...

  • Page 12: Wire Feeder´s Error Codes

    DISTURBANCE POSSIBLE CAUSE REMEDY The power source can´t reach Net fuse has blown Check the net fuses maximum output A faulty supply cable Check the supply cable A faulty main switch Check the main switch A faulty primary rectifier Check the primary rectifier. Measure the DC-link voltage during idling and under load (530…570 Vdc)

  • Page 13: Signals Between Power Source And Wire Feeder

    Voltages in the E-line of control cable between the power source and the wire feeder: Power source size Arc on-info Kempomig 3200 Kempomig 4000 During startup the wire feeder detects the power source size, based on the voltage level at E-line.
  • Page 14 Voltages in the H-line of the control cable between the power source and the wire feeder: Maksimi Minimi On MMA the wire feeder unit starts the power stage and develops an analog set value voltage of 0-10 V. Start Maximum Minimum Stop Post-current time minimum = 40 ms...
  • Page 15 Voltages in the I-line of the control cable between the power source and the wire feeder: On MMA the voltage of I-line is approx. + 10 V MIG/MAG dynamics - 9 MIG/MAG dynamics 0 MIG/MAG dynamics + 9 On MIG/MAG-process the voltage in I-line is approx. + 0,5 - 3,2 V, depending on the dynamics setting.

  • Page 16: Solenoid Valve Control

    Solenoid valve control The wf-unit develops control voltage for the solenoid valve, by pulsing approx. + 40 V voltage with Pulse ratio of 50 %. Wire feed motor control Wire feed speed minimum Wire feed speed 10 m/min Wire feed speed maximum The wf-unit controls the feed motor speed by PWM-principle.

  • Page 17: Torch Connection

    Welding gun connection The voltage ”direction” changes every 20 ms in the gun control circuit. On the negative half cycle the gun switch and temperature watch (PMT W) states are read. On the positive half cycle the state of an RMT 10 guncontroller is read. Startti Gun connection open Gun start (MT-type guns)
  • Page 18 PMT-connected and RMT in position 1 PMT-connected and RMT in position 3 PMT-connected and RMT in position 5 PMT –gun start and RMT in position 5...

  • Page 19: Signals From Wf-Unit´s Connectors

    Signals from Wf-unit´s connectors Remote controller connector XW101 Signal Explanation 30 Vac Supply voltage (fuse 6,3 A slow) 30 Vac Supply voltage (fuse 6,3 A slow) + 10 V Remote controller voltage reference 0 - 10 V Wire feed speed set value 0 - 10 V Set value to power source (current or voltage) Process selection...

  • Page 20: Cooling Unit Control

    Cooling unit control The cooling unit is controlled on only on MIG process, while start is active. Cooling unit stops the power stage if a missing coolnat pressure is detected or the coolant has overheated. Connector Signal X7/1 Cooling unit start (in start the power source control card A001 A001 pulls down the voltage on connector X7/1) X7/2...

  • Page 21: Power Source Control Card A001 Layout

    Power source control card A001 layout R39 Current max. R75 Inv. frequency R120 Voltage max. R150 Voltage min. R152 Current min. R150 R160 MMA ignition pulse R120 X16 Supply voltage selection, R152 R160 460 V X17 Supply voltage selection, 400 V X18 MMA characteristic curve for testing without a wire feeder unit...

  • Page 22: Msd 1-Meter Unit Layout

    MSD 1-meter unit layout R3 Set current minimi (no function with Kempomig-power sources) R4 Set current maximum (no function with Kempomig-power sources) R5 Voltage display R6 Current display X3 (no function with Kempomig-power source) X4 (no function with Kempomig-power sources)

  • Page 23: Notes

    Notes...

This manual is also suitable for:

Kempomig 4000wKempomig 3200wKempomig 4000Kempomig feed 400

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