Kemppi FastMig X 450 Service Manual Download Page 28 | Manualshive

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Kemppi FastMig X 450 Service Manual Download Page 28

SERVICE MANUAL

FASTMIG X

26 (37)

Kemppi OY

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

V6

V5

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Summary of Contents for FastMig X 450

Page 1: ...20 6 2013 Kemppi Oy SERVICE MANUAL FASTMIG X FASTMIG X 450 MXP37 PIPE MXP 38...

Page 2: ...SERVICE MANUAL KEMPACT RA Kemppi Oy...

Page 3: ...nectors 9 5 SECONDARY CUT OFF CARD Z004 10 5 1 Connectors 10 6 GATE DRIVER CARD A001 11 6 1 Auxiliary power supply 11 6 2 IGBT driver11 6 3 Auxiliary device connection 11 6 4 Voltage monitoring 11 6 5...

Page 4: ...Motor control card A001 21 1 6 Wire feed unit GT04 21 1 7 Memory card A003 21 1 8 Panel card P001 21 2 MOTOR CONTROL CARD A001 22 2 1 Power supply 22 2 2 Leds 22 2 3 Connectors 23 3 MEMORY CARD A003...

Page 5: ...ontroller Before removing any covers or commencing any testing or measurement disconnect the power source from the mains voltage Dangerous DC voltage may still exist after the removal of the input vol...

Page 6: ...3 A Suitable for generator use 35 kVA This equipment complies with IEC 61000 3 12 provided that the short circuit power Ssc is greater than or equal to 5 5 MVA at the interface point between the user...

Page 7: ...hoke saturates in certain voltage and current values Blocking diode V7 prevents dc link volt age from rising too high while turning on device The main transformer T001 has one primary winding 7 turns...

Page 8: ...Three phase rectifier V6 The three phase rectifier unit V6 rectifies the mains voltage 400V to DC link voltage Mean value of the DC link voltage is approx 540 V in normal operation conditions Rectifie...

Page 9: ...round X6 Main transformer X7 Main transformer X8 X15 IGBT gates and emitters X16 Primary choke X17 Primary choke X18 DC link voltage X19 DC link voltage X20 DC link voltage X21 DC link voltage X29 Cha...

Page 10: ...4 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 switch...

Page 11: ...recovery current snaps off The voltage stress is caused by leakage inductance and stray ca pacitance oscillation Capacitor C5 diode V17 and resistors R9 and R10 form a filter circuit which reduces op...

Page 12: ...mosfets sources are connected to main choke The isolated voltage 15Vdc in C7 is generated from 24Vdc by using forward converter with V1 and T1 Control gate signal is generated in the processor card A...

Page 13: ...it consists of drive transformers T1 and T2 which provide insulation between secondary and prima ry full bridge driving stage and latch circuit for negative gate voltage 6 3 Auxiliary device connectio...

Page 14: ...er X3 4 IGBT gate X3 5 Not Connected X3 6 IGBT gate X4 1 IGBT emitter X4 2 Not Connected X4 3 IGBT emitter X4 4 IGBT gate X4 5 Not Connected X4 6 IGBT gate X5 1 Fan M002 X5 2 Fan M002 X6 1 Fan M001 X6...

Page 15: ...Auxiliary voltage ground X16 5 Not connected X16 6 Auxiliary voltage ground X16 7 Over temperature LED X16 8 Over temperature LED X16 9 Power ON LED X16 10 Power ON LED X16 11 Spare supply voltage 24V...

Page 16: ...d on the measured secondary current and voltage Current and voltage measurements are controlled by FPGA Microcontroller also controls fans power on LED over temperature LED DC link overvoltage protect...

Page 17: ...supply output Differential voltage signal is brought to power source by connector X010 This connector leads the sig nal to processor card connector X11 The secondary voltage signal is scaled down fil...

Page 18: ...ignal active low X2 6 GND Shunt X3 Connects gate driver and processor card X9 1 Current transformer ac X9 2 Machine size jumper J1 X9 3 Machine size jumper J2 X9 4 Current transformer ac X9 5 Machine...

Page 19: ...is connected to this card There are 50DC bus and CAN bus in this connector DC DC converter generates 5Vdc in this card by transformer T2 Regulator N3 generates 3 3Vdc 8 2 Leds Led Description H1 Blin...

Page 20: ...econdary current is measured with the shunt resistor 10 3 Output RFI filter unit RC001 Capacitors C001 to C005 varistor R003 and two power resistors forms a radio frequency interference RFI unit to re...

Page 21: ...alculates time integral of the welding current This integral defines post run time of the fans Minimum post run time is 20s maximum 5min o MMA and Service mode fan1 is always on Fan2 starts 7s delay f...

Page 22: ...ulse power sources The special PipeRoot welding process is possible with FastMig X power source only There are two versions of MXP 37 Pipe feeder Steel and Stainless Stainless version has pulse MIG an...

Page 23: ...ible to determine motor 1 and 2 speed differences and so on notify if either of the motor wheel spins Micro controller calculates directly both motor currents and motor 2 control is based on same curr...

Page 24: ...are created from the 50V bus voltage 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 N...

Page 25: ...trol X4 5 Start Potentiometer Torch line 1 X4 6 5V Remote control X4 7 Not connected X4 8 System bus DATA X4 9 System bus DATA X4 10 Gas valve GND X4 11 Potentiometer 1 Remote control X4 12 Gas valve...

Page 26: ...ler and motor s speed of rotation can be calculated 4 1 Connectors Connector Description X1 5V X2 GND X3 Tacho signal 4 PANEL CARD P001 Panel card is connected to the motor control card A001 with 16 w...

Page 27: ...ool max weight 20 kg max 300 mm Gun connection Euro Operation temperature range 20 40 C Storage temperature range 40 60 C EMC class A Degree of protection IP23S Degree of protection 13 1 kg 625 x 243...

Page 28: ...Y 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 m...

Page 29: ...d bias and reverse bias condition to make sure they are fine Check the diodes using the multimeter diode function to measure their threshold voltage 0 3 0 6 V Measurings Positive test lead Negative te...

Page 30: ...sing the multimeter diode function to measure their threshold voltage 0 3 0 6 V When measuring IGBT unit diodes you must disconnect other end X7 of main transformer Measurings Positive test lead Negat...

Page 31: ...k positive voltage o E2 2 Emulates DC link negative voltage o B1 4 TR1 gate control signal positive o B2 6 TR2 gate control signal negative o C2E1 1 Pos Neg output voltage measuring Measurings IGBTs 1...

Page 32: ...Disconnect main transformer secondary side wires from Z003 card Remember to test diodes both ways forward bias and reverse bias Measurings Positive test lead Negative test lead Result X1 Z003 heatsin...

Page 33: ...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...

Page 34: ...up and DC link voltage can be measured Z002 X1 and X3 5 MAIN COMPONENTS INSTALLATION Heat sink paste should be spread on to the modules in an even layer by using clean fingers Then the card should be...

Page 35: ...n process Power source not support that process 11 Cut Off card Z004 control error Cut Off card faulty card connector loosen Switch machine ON OFF 12 Welding cable fault Welding circuit in short circu...

Page 36: ...or not identified Check the connection to power source 81 Welding program not found If welding program is required please order proper welding program and license MEM ERR Error while reading or writi...

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