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Kemppi KEMPACT 181A, Service Manual, Page: 29 / 40

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SERVICE MANUAL 
 
KEMPACT RA_V_1.2 

28 (40) 

 

 

 

 

 

 

 
 

 
Kemppi Oy 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

7. PANEL CARD P001 
 

•

 

Panel card is connected to the control card A001 connector  with 16-wire ribbon cable 

 
7.1. Connectors 
 

Pin 

Signal 

Description 

X1:1 

+24V 

+24V supply voltage for the LCD backlight 

X1:2 

SDA 

I2C bus data 

X1:3 

+5V 

+5V supply voltage 

X1:4 

GND 

Ground 

X1:5 

SCL 

I2C clock 

X1:6 

GND 

Ground 

X1:7 

Pot_1_A 

Pulse potentiometer 1 channel A 

X1:8 

Pot_1_B 

Pulse potentiometer 1 channel B 

X1:9 

GND 

Ground 

X1:10 

Pot_2_A 

Pulse potentiometer 2 channel A 

X1:11 

Pot_2_B 

Pulse potentiometer 2 channel B 

X1:12 

GND 

Ground 

X1:13 

Pot_3_A 

Pulse potentiometer 3 channel A 

X1:14 

Pot_3_B 

Pulse potentiometer 3 channel B 

X1:15 

+5V 

+5V supply voltage 

X1:16 

+24V 

+24V supply voltage for the LCD backlight 

 

 

Summary of Contents for KEMPACT 181A

Page 1: ...Kemppi Oy SERVICE MANUAL KEMPACT RA 181A 251R 251A 253R 253A 323R 323A 253MV 323MV...

Page 2: ...1 15 3 1 17 Output RFI filter C001 C002 15 3 1 18 Output terminal X004 15 3 1 19 Euro connector X005 15 3 2 Main circuit diagram 181 251 models 15 3 2 1 PFC Choke L002 15 3 2 2 PFC circuit auxiliary t...

Page 3: ...are compact MIG MAG welding machines designed for professional use The power source part of the machine is based on inverter technology IGBTs are used as power switches in the inverter Kem pact RA we...

Page 4: ...SERVICE MANUAL KEMPACT RA_V_1 2 3 40 Kemppi Oy 1 PARTS OF MACHINE Kempact RA 253 323...

Page 5: ...SERVICE MANUAL KEMPACT RA_V_1 2 4 40 Kemppi Oy Kempact RA 253 323 NOTE Spare part info available from spareparts kemppi com email...

Page 6: ...ED 140A 21V 0 82 150A 21 5V 0 82 Wire feed speed adjustment range 1 0 14 0m min 1 0 18 0m min Voltage adjustment range 8 0 26 0V 8 0 29 0V Filler wires Fe solid 0 8 1 2 mm 0 8 1 2 mm Fe cored wires 0...

Page 7: ...88 190A 23 5V 0 86 Wire feed speed adjustment range 1 0 18 0m min 1 0 20 0m min Voltage adjustment range 8 0 31 0V 8 0 32 5V Filler wires Fe solid 0 8 1 2 mm 0 8 1 2 mm Fe cored wires 0 8 1 2 mm 0 8 1...

Page 8: ...10V 20A 31V 250A 10V 20A 32 5V 320A No load voltage 46V 50V Idle power 35W 35W Power factor at max 250A 26 5V 230V 0 94 320A 30V 230V 0 94 250A 26 5V 400V 0 93 320A 30V 400V 0 94 Efficiency at 100 ED...

Page 9: ...ICE MANUAL KEMPACT RA_V_1 2 8 40 Kemppi Oy range Storage temperature range 40 60 C 40 60 C Standards IEC 60974 1 IEC 60974 1 IEC 60974 5 IEC 60974 5 IEC 60974 10 IEC 60974 10 IEC 61000 3 12 IEC 61000...

Page 10: ...SERVICE MANUAL KEMPACT RA_V_1 2 9 40 Kemppi Oy 2 2 Main circuit diagrams...

Page 11: ...SERVICE MANUAL KEMPACT RA_V_1 2 10 40 Kemppi Oy...

Page 12: ...SERVICE MANUAL KEMPACT RA_V_1 2 11 40 Kemppi Oy Please refer to Kemppi Channel for the latest version of main circuit drawings...

Page 13: ...r a test run after a short delay 4 Welding is enabled Kempact RA machines have following parts and components Terminal block X001 Varistors R001 Main switch S001 Terminal block X009 Main circuit card...

Page 14: ...181 and 251 machines 400V input is used in 253 and 323 machines Auxliary transformer output voltage is rectified using rectifier bridge G003 Both the auxiliary transformer and the rectifier bridge ar...

Page 15: ...e gun When the user pushes start button wire feed motor and the power source start Wire feed speed is creep start speed which is slower than normal wire feed speed If arc is not established during fir...

Page 16: ...he component frame 3 2 3 Main circuit card Z001 3 2 3 1 EMC Filter Capacitors C7 C10 C15 C16 and inductor T6 form an EMC filter The purpose C17 and R18 is to dampen common mode transients coming from...

Page 17: ...r source is switched on R1 is bypassed with relays K1 and K2 after DC link capacitors C17 C18 have been charged Relays K1 and K2 are controlled with the microcontroller 3 3 1 3 IGBT driver IGBT driver...

Page 18: ...SERVICE MANUAL KEMPACT RA_V_1 2 17 40 Kemppi Oy...

Page 19: ...K1 and K2 after DC link capacitors have been charged Relays K1 and K2 are controlled with the microcontroller 3 4 2 3 IGBT driver IGBT driver consists of gate transformers T2 and T3 and surrounding c...

Page 20: ...Mains voltage Main voltage connector X2 Mains voltage Mains voltage connector Pin Signal X4 Chassis ground connector Pin Signal X5 Auxiliary transformer connection auxliary transformer is protected w...

Page 21: ...ther end X10 4 Inrush Relay Other end of the inrush relay coil X10 5 OV Opto N Over voltage optocoupler other end X10 6 Primary current transformer Primary current transformer other end X10 7 IGBT Dri...

Page 22: ...e connector X3 Mains voltage Mains voltage connector Pin Signal X4 Chassis ground connection Pin Signal X5 Auxiliary transformer connection auxliary transformer is protected with PTC resistors R16 and...

Page 23: ...IGBT Drive B Other end of the IGBT driver transformer primary X9 2 OV Opto P Over voltage optocoupler other end X9 3 Inrush Relay Other end of the inrush relay coil X9 4 IGBT Drive A Other end of the...

Page 24: ...X2 X21 Mains voltage Mains voltage connector X3 X22 Mains voltage Mains voltage connector Pin Signal X4 Chassis ground connection Pin Signal Description X5 Auxliary transformer connectors Auxliary tr...

Page 25: ...X10 4 Inrush Relay Other end of the inrush relay coil X10 5 X10 6 Primary current transformer Primary current transformer other end Pin Signal X11 PFC choke connections X12 PFC choke connections Pin S...

Page 26: ...5 SECONDARY RECTIFIER CARD Z002 5 1 Connectors Pin Signal X1 Main transformer secondary X2 Main transformer secondary X3 Z002 card connection to secondary profile X4 Z002 card connection to secondary...

Page 27: ...driver when this LED is lit IGBT driver is active H4 RDI debug purposes H5 Motor control input voltage H6 24V voltage 6 2 Connectors Pin Signal Description X2 1 50 V Secondary voltage from secondary...

Page 28: ...on X4 8 PFC control PFC ON OFF control connection X4 9 Inrush relay Inrush relay connection X4 10 Brights led Brights led card P002 connection X4 11 PFC control PFC ON OFF control connection X4 12 Inr...

Page 29: ...X1 3 5V 5V supply voltage X1 4 GND Ground X1 5 SCL I2C clock X1 6 GND Ground X1 7 Pot_1_A Pulse potentiometer 1 channel A X1 8 Pot_1_B Pulse potentiometer 1 channel B X1 9 GND Ground X1 10 Pot_2_A Pul...

Page 30: ...s using the multimeter diode function to measure their threshold voltage 0 3 0 6 V Measurings 1 Positive test pole to rectifier pole 1 red negative test pole to rectifiers poles 1 black one at time Re...

Page 31: ...maged When measuring IGBT unit diodes you must disconnect other end of main transformer X7 o After measuring connect other end X7 back Measurings 1 Positive test pole 1 red to connector X16 negative t...

Page 32: ...imeter diode function to measure their threshold voltage 0 3 0 6 V Measurings 1 Positive test pole to DC link negative test pole to L1 L2 L3 one at the time Result 0 3 0 6 diodes Ok 2 Positive test po...

Page 33: ...y may be defective if IGBT is damaged When measuring IGBT unit diodes you must disconnect other end of main transformer X7 o After measuring connect other end X7 back Measurings 1 Positive test pole t...

Page 34: ...s 1 Negative test pole to rectifier pole 1 black positive test pole to rectifiers poles 1 red one at time Result 0 3 0 6 diodes Ok 2 Positive test pole to rectifier pole 3 red negative test pole to re...

Page 35: ...ng IGBT unit diodes you must disconnect other end of main transformer X7 o After measuring connect other end X7 back Measurings 1 Negative test pole 1 black to connector X19 positive test pole 1 red t...

Page 36: ...easure them in two separate groups Measurings 1 Positive test pole to main transformer secondary secondary card connectors X1 and X2 one at time negative test pole to secondary profile Result 0 3 0 6...

Page 37: ...voltages can be quickly verified with LEDs on the control card A001 9 MAIN COMPONENTS INSTALLATION Heat sink paste should be spread on to the modules in an even layer by using clean fingers Then the...

Page 38: ...profile to component frame 2 NM Main transformer secondary leads 5 NM 9 3 Other components Main transformer T001 to component frame 2 NM Main transformer T001 secondary leads to secondary card Z002 X...

Page 39: ...EEPROM memory error used wrong welding parameters improper value start up machine on off check welding parameters 8 Memory channel 1 error memory channel data is invalid corrupted start up machine on...

Page 40: ......

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