Kemppi Kempact Pulse 3000 Bedienungsanleitung

Service manual

Ver. 1.3.2

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………. 11,12

Secondary diode card Z002

Functions / connectors ...………………………. 13

Layout………………………………………….. 13, 14

Voltage after the secondary diode card Z002 …. 14, 15

Control card A001

Functions / connectors ………………………….16, 17

Layout………………………………………….. 17

IGBT gate pulses…..……………………………18

Control card A002

Functions / connectors ………………………….19

Layout………………………………………….. 19

Wf- speed min and max adjustments…………... 20

Panel

Panel testing....................………………………. 21

Wf-motor current measuring...............………….21

Layout………………………………………….. 21

Structure….......………………………………………….. 22

IGBT testing …………………………………………….. 23

IGBT replacing…………………….......………………... 24

Notes……………………………………………................ 25

technical data

Supply voltage 3400 V

15% , 50/60 Hz

Loadability

(connection power)

40% ED 250 A / 26,5 V (12 kVA)

60% ED 207 A / 24 V (10 kVA)

100% ED 160 A / 22 V (7,5 kVA)

Supply cable(fuse) 4 x 1,5 mm22,5 m (16 A slow)

Welding voltage adj. range 8 - 30 V

Wf-speed adj. range 1 - 18 m/min

Power factor 0,69

Efficiency 0,84

Filler wires

Fe, Ss

FCW

CuSi

0,6…1,0 mm

0,9…1,2 mm

0,8…1,0 mm

Wire spool diameter (weight) 300 mm (15 kg)

Dimension(weight) L580 x W280 x H440 (22 kg)

OCV Approx. 57 V

Switches and connectors

Optical tachometer

Wf-motor

Pressure adjustment screw

Feed rolls

Gear wheel (18…24 m/min)

EURO-connector

Plus ( + )

Minus ( - )

Return current connector

Euro-connector

On/off-signal lamp

Overheat protection sign Net voltage over / undervoltage sign

2T/4T-tmethod selection

Setup (long press)

Aux. functions selection:

Crater fill

Hot Start

Spot timer Memory channels (100)

Process selection:

Double pulse

Pulse-MIG

1-MIG

Dynamics Gas test

Local / remote control

Wire inch

Plate thickness-/current

display selection

Adjustable parameter selection

Wf-speed

Voltage

Arc length

Chosen parameter adjustment

Panel

Selecto (5-channels)

Synergic curve number

Jumper number (Setup)

Synergic curve selection

Wf-speed

Voltage

Synergic curve material group

Jumper name (Setup)

Extra info of

synergic curve:

Material group

Wire diameter

Material type number

Gas type

Last welding value

Plate thickness -/

welding current display

Selected parameter

s value display

Synergic curves

1-MIG Pulse-MIG Program Material Gas

X 00 All All All

SS-group

0,8

0,9

SS 308 / 316 Ar + 2% C02

Al-group

X X A1 1,0 AlMg 5 / AlMg 4,5Mn Argon

X X A2

1,0

AlMg 5 / AlMg 4,5Mn Argon

X X A6

1,2

AlSi 5 / AlSi 12 Argon

X X

1,2 AlSi 5 / AlSi 12 Argon

Cu-group

X X

0,8 CuSi 3 Argon

X X C3 1,0 CuSi 3 Argon

Fe-group

0,8

1,0

0,8

1,0

Metal core wire

Ar + 25% C02

C02

Normal-MIG 01 All All All

X X S3 1,0 SS 308 / 316 Ar + 2% C02

X X F2 0,9 Fe Ar + 25% C02

SETUP-functions

Error codes

Err 3 Net overvoltage

Err 4 Power source overheated

Err 5 Cooling unit has stopped welding

Err 6 Power source output voltage is has risen > 80 Vdc

Err 153 PMT-gun overheated or RMT 10 installed and PMT-gun in FU-position. In some cases this error may

be presented if one of the main supply voltage phases are missing.

Err 154 Wf-motor overload (current > 4,5 A/ 5 s.)

Parameter selection Parameter adjustment

10 s.

The SETUP is entered by pressing the setup-button for 10 seconds.

Adjustable parameter

Post gas time

Pre gas time

Hot Start level

2T Hot Start duration

Crater fill end level

Crater fill time (angle)

Creep start starting level

Creep start time (angle)

Doublepulse freq.

Double pulse Wf-speed amplitude

Ignition pulse

Pulse top current

Post current time

Arc length adj. range

Calibration

Maximum wf-speed

Liquid cooled gun PTC

Gun controller automatic detection

Display recovery delay

Number Display

Syn

Adj. range Quantity

99Factory settings recall

PoG

PrG

Hot

H2t

CFL

CFS

CSL

CSS

dFr

StP

PuC

PoC

ALr

CAl

Gun

GrE

dIS

FAC

Factory setting

Syn

2.0

Syn

5.0

OFF

0.0…9.9

-50…+75

0.1…9.9

10…90

1…20

10…90

0.1…5

0.0…8.0

0.0…3.0

-9…0…+9

-10…+15

0.0…10

-50…+75

1.0

18 tai 25

On/Off

1.0…20

Off/Pan/All

s/10m/min

m/min

V/100A

m/min

Err 253 Wrong welding process

+ t

X27

X24

X30

+ t

X11

X10

X18

C10

C13

C11

C12

1 2

3 4

R13

X19 X20

C4C3

R12R11

C2C1

R10R9

X21

X22

X23

Main circuit

Primary circuit.

Secondary circuit.

C2 R6

V10

C1 R5

X3 X4

Main circuit 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. Check the net fuses and supply cable

condition.

Power source can´t provide full

power.

Net fuses or supply cable.

Main transformer T001 or

secondary siode card Z002.

Check the net fuses and supply cable

condition.

Check the main transformer T001´s

ferrites and secondary diode card

diodes.

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

X9 Fan M002

X10 and X11 Aux. transformer T002

X12, X14 and X17 Net voltage 400 Vac

X13, X15 and X16 Main switch S001

X18 Protective earth

X19 and X20 Charge relay

X21 and X22 Main transformer T001

X23 Intermediate circuit DC-voltage

X24, X27 and 30 Main switch S001

Main circuit card Z001 layout X1

X10

X11

X18

X20

X19

X30

X24

X27

X23

X22

X21

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