Kemppi 3200 User manual

Service manual

Ver. 1.0

FEED 400

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

Power source control card A001 layout..…...…………..21

Wire feed unit control card A001 layout………………..21

MSD 1-meter unit layout..……………………...………...22

Notes……………………………………...………………..23

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. Feed-unit´s all functions are programmatically controlled.

General

Technical data

Supply voltage 3~ 50 / 60 Hz 400 V +10….-15 % 3~ 50 / 60 Hz 400 V +10….-15 %

Connection power 13,4 kVA / 320 A (50 % ED) 18,4 kVA / 400 A (40 % ED)

Supply cable/fuses 4 x 2,5 S / 16 A slow 4 x 2,5 S / 16 A slow

Loadability 320 A / 32,8 V (50% ED)

250 A / 30,0 V (100% ED) 400 A / 36,0 V (40% ED)

250 A / 30,0 V (100% ED)

Welding current adj. range 10 A – 320 A (MMA) 10 A – 400 A (MMA)

Welding voltage adj. range 10 V – 35 V (MIG) 10 V – 40 V(MIG)

Max. welding voltage 40 V / 320 A (MMA) 40 V / 400 A (MMA)

OCV approx. 75 V approx. 75 V

Idling power < 55 W < 55 W

Degree of protection IP 23C IP 23C

Measures

Length 940 mm 940 mm

Width 515 mm 515 mm

Height 880 mm 880 mm

3200 4000

Water tank volume 3 l

Cooling power 620 W

Max. pressure 400 kPa

Max. flow 4 l / min.

3200W/4000W

Supply voltage 30 Vac 50/60 Hz (150 VA)

Loadability 60% ED

100% ED

400 A

310 A

Wf-speed 0,5…18/25 m/min

Wire spool (max) 20 kg (φ300 mm)

Weight 15 kg

Measures Length

Width

Height

570 mm

210 mm

440 mm

FEED 400

14 15 16

Switches and connectors

1 Process selection

2 Local / remote control selection

3 Wire feed speed-/ plate thickness display

4 Wire feed speed -/ power adjustment

5 Voltage -/arc length -/ current setting

6 Local / remote control

7 Voltage -/ current set value display

8 Dynamis adjustment, MIG/MAG

9 Synergic program number

10 On/off-signal lamp

11 Overheat signal lamp

12 Dynamics adjustment, MMA

13 Cooling method selection

14 MSD 1-meter unit

15 Coolant overheat signal lamp

16 Cooling unit test switch

17 Missing pressure signal lamp

18 Main switch S001

19 Welding current connection

20 Welding current connection

21 Control connection (amphenol 10-pin)

22 Control connection fuse 6,3 A, slow

23 Cooling unit fuse 2 A, slow

24 Coolant connector, pressure

25 Coolant connector, return

456789

1 2 3

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. When the upper IGBT (V2) is

conductive, there is positive voltage in the main transformer´s (T1) primary, and when the lower

IGBT (V3) is conductive there is negative voltage in the main transformer´s (T1) primary.

Power is adjusted by changing the IGBT timings (PWM). Main transformer T1 secondary

voltages are rectified with a full-waverectifier. UG2

UG3

UG2

UG3

approx. + 570 V

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. 17 kHz

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. 17 kHz

Voltage after secondary diodes

C = Voltage after the secondary diodes

(10 A / 20,4 V, MMA)

Frequency approx. 35 kHz

CC = Voltage after the secondary diodes

(100 A / 24,0 V, MMA)

Frequency approx. 35 kHz

Voltage after secondary diodes

C = Voltage after secondary diodes

(320 A / 32,8 V, MMA)

Frequency approx. 35 kHz

CC = Voltage after secondary diodes

(400 A / 36,0 V, MMA)

Frequency approx. 35 kHz

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.

DISTURBANCE POSSIBLE CAUSE REMEDY

The machine won´t start. WF-

unit´s displays remain blank. Net fuse has blown

Faulty supply cable

Faulty main switch

Faulty aux. transformer

Faulty intermediate cable

Check the net fuses

Check the supply cable

Check the main switch

Check the aux. transformer

Check the intermediate cable

between power source and wf-unit

The fuses blow during machine

startup. A faulty primary side power

semiconductor

A faulty main circuit card

A faulty aux. transformer

A faulty secondary unit

Check the primary rectifier and

IGBT-module condition

Check the load capacitors. See, if

there are marks of insulation

damages on the main circuit card.

Check the aux. transformer

Check the secondary diodes

The machine welds, but displays

remain blank. Faulty flat cable

Faulty operating panel

Check flat cables & connectors

between control card A001 and

operating panel.

Replace the operating panel

Power source stays on MMA,

even though MIG is selected by

the panel.

Faulty flat cables

Faulty synergy card P002

Check flat cables & connectors

between control card A001 and

operating panel.

Disconnect the flat cable from P002

synergy card. As a result of this, if

the power source goes to MIG, then

replace the P002.

Troubleshooting diagram

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