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Kemppi Kempact Pulse 3000, Service Manual, Page: 7 / 25

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Kemppi Kempact Pulse 3000 Service Manual Download Page 7

+ t

L2

X27

X24

X30

+

 t

X

11

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10

X9

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C8

C1

0

C1

3

C9

C1

1

C1

2

5

6

7

1

2

3

4

V2

C6

C7

R13

X19

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L1

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C3

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G3

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E3
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Main circuit 

Primary circuit. 

Secondary circuit. 

U

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R6

V1

V2

V3

V4

V5

R4

R3

V6

V7

V8

V9

V10

C1

R5

X1

X2

X3

X4

R1

R2

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U

7 

Summary of Contents for Kempact Pulse 3000

Page 1: ...Service manual Ver 1 3 2...

Page 2: ...ransformer 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 Layo...

Page 3: ...160 A 22 V 7 5 kVA Supply cable fuse 4 x 1 5 mm2 2 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 Al CuSi 0 6 1 0...

Page 4: ...t 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 puls...

Page 5: ...rgic curves 5 1 MIG Pulse MIG Program Material Gas X 00 All All All SS group X X X X S1 S2 0 8 0 9 SS 308 316 Ar 2 C02 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...

Page 6: ...vel 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 Ca...

Page 7: ...6 7 1 2 3 4 V2 C6 C7 R13 X19 X20 L1 C4 C3 R12 R11 C2 C1 R10 R9 X2 G3 X8 G1 X3 G4 X6 G2 X1 E3 X7 E1 X21 X22 X4 E4 X5 E2 V1 X23 R5 Main circuit Primary circuit Secondary circuit U C2 R6 V1 V2 V3 V4 V5...

Page 8: ...Main circuit diagram 8...

Page 9: ...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 fuse...

Page 10: ...odule 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...

Page 11: ...0 V Full bridge IGBT 4 x 75 A 1200 V Primary rectifier 50 A 1600 V Varistors 3 x 550 V DC link charging resistor and relay Main switch EMI filter Main transformer T001 primary voltage a Main transform...

Page 12: ...T001 primary voltage with values 50 A 16 5 V Synergic curve 00 meas point a a Main transformer T001 primary voltage Main transformer T001 primary voltage with values 250 A 26 5 V Synergic curve 00 me...

Page 13: ...002 has these operational blocks Secondary rectifying Machine size coding Overvoltage protections Dampening circuits Connectors X1 and X2 Main transformer secondary X3 and X4 Euro connector X5 X7 Mach...

Page 14: ...Secondary diode card Z002 layout Fast diode 10 x 60 A 400 V Varistor 2 x 175 V Voltage after the secondary diode card Z002 b 14...

Page 15: ...ondary diode card Z002 b Voltage after the secondary diode card with values 50 A 16 5 V Synergic curve 00 meas point b c Voltage after the secondary diode card with values 250 A 26 5 V Synergic curve...

Page 16: ...Panelbus transmit X1 7 Empty X1 8 Empty X1 9 Serial bus 1 transmit X1 10 Serial bus 1 receive X1 11 Empty X1 12 Empty X1 13 Empty X1 14 Panel bus receive X1 15 5 V X1 16 GND X2 1 CNVss X2 2 Empty X2 3...

Page 17: ...GND X16 3 GND X16 4 Empty X16 5 Empty X16 6 Wire feed on off control X16 7 Cooling unit alarm X16 8 Wf motor current measuring X16 9 24 V X16 10 Cooling unit on off control X16 11 Wf motor speed set v...

Page 18: ...IGBT gate pulses Gate pulse in idling measuring point c c Z001 c A001 18...

Page 19: ...ction Connectors X1 1 15 V X1 2 Wf motor plus X1 3 Main transformer aux coil X1 4 5 Vref2 X1 5 Wf speed set value X1 6 Main transformer aux coil X1 7 GND X1 8 Wf motor current X1 9 Main transformer au...

Page 20: ...er R32 7 Re check maximum and minimum If not using load bank you have to check creep start level because of without short circuit creep start won t upslope to the welding value 1 From panel choose syn...

Page 21: ...anel layout X10 X11 X1 X1 Flat cable panel power source X10 Programming connector panel X11 Programming connector power source Panel switches LEDs and displays can be tested After turning the power so...

Page 22: ...Structure 22 A001 Control card L002 Sec choke Z002 Secondary diode card Z001 Main circuit card A002 Control card Y001 Solenoid valve M002 Fan S001 Main switch R001 Shunt P001 Panel...

Page 23: ...4 X5 E2 C1 3 C2E1 1 B1 4 X1 X2 G3 X3 G4 X4 X5 X6 G2 X7 X8 G1 X22 X21 C1 C1 E2 E2 B2 6 E2 2 X2 G3 X8 G1 X3 G4 X6 G2 X1 E3 X7 E1 X21 X22 X4 E4 X5 E2 C1 3 C2E1 1 B1 4 B2 6 E2 2 IGBT module can be tested...

Page 24: ...bly destruction Heat transfer paste is spread as an even layer about 0 1 mm thick onto the modules base plate The module is immediately attached to the heat sink in order to avoid any dirt to get betw...

Page 25: ...Notes 25...

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