Kemppi 3200 Operating manual

TECHNICAL SERVICE

MANUAL FOR

KEMPOWELD MACHINES

TECHNICAL SERVICE MANUAL FOR KEMPOWELD

GENERAL MAINTENANCE OF KEMPOWELD

Maintenance of Kempoweld power source will normally consist of general cleaning

of unit with soft brush and vacuum cleaner, and checking of wearing for parts like:

switches,connectors, potentiometers and fuses. NOTE! If you use compressed air

for cleaning, there is a risk that dirt is packed even more tightly into gaps of

connectors or components, so be carefull with those parts!

Maintenance of the wire feeder and mig gun will normally consist of general

cleaning and change of consumable parts like: contact tube, contact tip,

contact tip adapter, gas nozzle, wire conduit, feeding rolls, guide tubes, and gear

wheel.

The number of machines in will determine to what extend consumable- and spare

parts will be stocked.

WARNING

Watch out for the mains voltage! Disconnect the power source from mains voltage

before removing cover plates or any testing or measurement and before

troubleshooting look for signs of over heating, fractures and damages from internal

components and power semiconductors.

TROUBLESHOOTING CHART

TROUBLE CAUSE REMEDY

The KEMPOWELD won´t start at all,

any of the auxiliary devices won´t

start.The signal lamps of machine

are not switched on.

Blown fuse in mains supply voltage.

Faulty mains cable.

Broken main switch.

Faulty auxiliary transformer T002 or

bad connection in connector X9,

400V or 0V.

Blown fuse F001 8A.

Check all three supply voltage

phases; check fuses.

Check mains voltage from terminal

block X001, repair cable if needed.

Check the main supply voltage

before and after main switch, change

switch if needed.

Check transformer, repair

transformer connection or change

if needed.

Check fuse and change if needed.

The wire feeding unit K200/400

won´t work.

Faulty connection in control lines.

Blown fuse F001 8A.

Broken PCB.

See, TABLE FOR CONTROL

LINES, table 1.

Check/change fuse F001.

See, TROUBLE SHOOTING FOR

PCBs appendix 1.

TECHNICAL SERVICE MANUAL FOR KEMPOWELD

TROUBLESHOOTING CHART

TROUBLE CAUSE REMEDY

The cooling unit don´t start or pilot

lamp Hw3 lacking water pressure is

iluminated.

Blown fuse F002 2A.

Auxiliary transformer T002.

Pressure switch S005

5µF capacitor C001.

Broken PCB.

Check and change the fuse if

needed.

Check the voltage from transformer

in the terminal block between 2.1

and 2.2, it should be 230v.

Check the voltage over the pressure

guard or from PCB A002 X2/1 and

X2/8; enough pressure 0V and lack

of pressure c. 5V.

Check and change the capacitor if

needed.

See, TROUBLE SHOOTING FOR

PCBs appendix 1.

The solenoid valve Y001 don´t work. Faulty solenoid valve or PCB A001. Check the 24 VDC from connector

X3/5 and X3/6, change valve or

PCB.

Wire feeding motor don´t work. Blown fuse F001 8A

The control cable between feeder

and power souce is broken or it is

not properly tightened.

Faulty motor or PCB A001in

K200/400.

Broken PCB.

Check/change the fuse if needed.

Check and repair the control cable if

needed. See table 1.

Check the motor voltage from A001

X4/12 and X4/13 max. is c. 24 VDC,

if it´s all right motor is faulty.

See, TROUBLE SHOOTING FOR

PCBs appendix 1.

Welding quality is bad:

- arc is not stable

- there are lot of spatters

- bad arc start

- not enough arc voltage

One phase is missing.

Faulty main transformer T001.

Faulty main switch S001 or contactor

K001.

Shielding gas is missing.

Gas hose of the gun is leaking or

connection is loose.

Broken diode in the secondary.

rectifier G001.

Check all phases from the therminal

block X001. Change mains fuse if

needed or tighten mains cables.

Check that voltages are symmetric

over the three spools of T001.

Variation of voltage is depending on

voltage selection and load; normally

it is between 10 VAC and 32 VAC.

OCV variation range is 11 VAC

to 35 VAC

Measure first main switch if it is all

right check the contactor.

Check the valve according the

instructions mentioned above.

Check/repair the mig gun.

Check and change diode(bridge)

if needed.

TECHNICAL SERVICE MANUAL FOR KEMPOWELD

TROUBLESHOOTING CHART

TROUBLE CAUSE REMEDY

Welding stops occasionally or some

other occasional disturbances.

Faulty intermediate cable or

connector.

Faulty switch in mig gun.

Loose start wire(s) in mig gun.

Check/repair the cable. See TABLE

FOR CONTROL LINES, table 1.

Check and change the switch if

needed.

Check and tighten the start wire(s)

inside the gun.

Machine is overheating because the

fan don´t start.

Faulty fan or PCB A001 . Check the 24 VDC voltage from fan

connector X2/12 and X2/13, if it is all

right change the fan, if it is not

change the PCB.

See, TROOUBLE SHOOTING FOR

PCBs appendix 1.

Wire feeding speed set value can´t

adjusted.

The set value potentiometer RW102

is faulty.

Check and change the 10KΩ

set value potentiometer RW102 if

needed.

KMW-sync is not working. Faulty connection in connector X1. Check and repair connection

according to PICTURE 1.

If some other push-pull gun than

Binzel or Hulftegger is in use the gun

is pulling to fast.

Wrong motor voltage. Select correct jumper combination

(there are two jumpers X1 and X2

and the fine adjustment for voltage

can made from MP-SYNC PCB)

from MP-SYNC control card. See

also PICTURE 2.

MSD-1 meter unit don´t work. Ribbon cable between MSD-1 and

control card A001 is loose or cut.

Faulty MSD-1 unit.

Check and tighten the cable, check

also the control voltage for MSD-1

from A001 X3/16 and X3/1 the value

should be 12 V.

Check as mentioned above if it´s all

right, chage the MSD-1.

Occasional disturbances with KMW-

timer unit.

Ribbon cable between KMW-timer

and control card A001 is loose or

cut.

Faulty KMW-timer unit.

Check and tighten the ribbon cable.

Check and change the KMW-timer

unit. See also potentiometers from

PICTURE 3.

The water circulation stops after 5 s

of welding.

Low cooling water volume.

Air bubbles or leakages in cooling

system.

Faulty pressure switch

Check the water and fill it if needed.

Follow the instructions of

Kempoweld Operation Instructions/

Operation Disturbances.

Check/change the pressure switch.

TECHNICAL SERVICE MANUAL FOR KEMPOWELD

TABLE 1. CONNECTORS AND CONTROL LINES

KEMPOWELD CONNECTORS X006 AND K200/400 XW101

XW101 / X006 K200/400

A001

KEPOWELD

A001

VALUE

BX3/1 X8/3 30 VAC

CX3/8 X2/1 30 VAC

DX3/7 X2/11 START

PICTURE 1. KMW-SYNC CONNECTION

HC-start

TECHNICAL SERVICE MANUAL FOR KEMPOWELD

PICTURE 2. A004 MP-SYNC CONTROL CARD

004

PICTURE 3. PCB OF K400 TIMER UNIT

R 11

R 15

R 19

Potentiometers: R11 = Gas post flow

R15 = Cycle time

R 19 = Pause time

TECHNICAL SERVICE MANUAL FOR KEMPOWELD

PICTURE 4. A001 PCB OF K400

Potentiometer: R24 = Adjustment of wire feed speed

C4 C5 C6

R24

TECHNICAL SERVICE MANUAL FOR KEMPOWELD

APPENDIX 1. TROUBLESHOOTING FOR PCBs

A001 POWER SOURCE

1. + 24 V over the capacitor C9

2. + 24 V over the capacitor C7 (FAN POWER SUPPLY)

3. + 15 V over the over the diode V2

4. + 12 V over the capacitor C10 (MSD POWER SUPPLY)

5. START => pin X2/11 to GND, 0V = start active

6. START => V4 to GND, 0V = start active

7. TP 4 = 15 V, FAN ON CONTROL

8. FAN TIMER voltage over C3 under 5 V = stop, over 10 V = on

A001 WIRE FEEDER

1. 30 VAC between the thyristros anodes

2. + 40 V over the capacitor C3

3. + 15 V over the diode V17

4. SYNCRONIZATION TP 19 (rectified sine wave)

5. RAMP WAVE over the capacitor C11 (the wave is only active when start

or wire feeding is on)

6. START TP13; 0V ON, 15 V STOP

7. BREAK CONTROL TP24 ; OV active 15 V stop

8. BURN BACK/POST GAS TIMER TP33; 15 V stop, under 2V on

9. CONTACTOR CONTROL TP 32; under 1 V off, over 5 V on

10. I FAN CONTROL TP 34; under 1 V off, over 10 V on

II FAN CONTROL, voltage over the capacitor C17 < 2 V fan off

< 6V fan on

11. SET VALUE FOR WIRE FEEDING SPEED pin X2/1 and GND; voltage between

0 V - 15 V depending on potentiometer setting

TECHNICAL SERVICE MANUAL FOR KEMPOWELD

A002 WATER COOLING UNIT

1. + 24 V over the capacitor C5

2. + 15 V over the capacitor C6

3. START TP 1 => 15 V

4. PRESSURE SWITCH pin X2/1 to GND; 0V pressure OK, 24 V no pressure

5. THERMAL PROTECTION between pins X2/3 and X2/6; 0.1 V - 0.3 V normal

temperature, over temperature over 3V

6. PUMP TIMER; TP 3 on > 5 V

off < 1 V

TP 18 on ≈0.6 V

off < 0.2 V

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