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Kemppi WELDFORCE KPS 3500, Service Manual, Page: 5 / 18

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Kemppi WELDFORCE KPS 3500 Service Manual Download Page 5

Simplified main circuit diagram

V1
V2

V1

V2

Control card A001

L1

L2
L3

The filter card Z004 dampens the electromagnetic disturbances conducting to the net (EMI).
Varistors (550 V) form an overvoltage protection against low energy voltage spikes. Note! Filter
card Z004 and varistors are mounted before the main switch S001!

Main circuit components

Filter card Z004

Varistors (550V)

Main switch S001

5

Summary of Contents for WELDFORCE KPS 3500

Page 1: ...Service manual Ver 1 0...

Page 2: ...components 5 8 Control cable connectors 9 Troubleshooting diagram 10 Control card A001 layout 11 Control card A001 jumper 11 12 Control card A001 leds 12 IGBT gate pulse 13 Voltage over the lower IGB...

Page 3: ...V 300 A 46 V 400 A 50 V 500 A OCV appr 65 V appr 65 V Appr 65 V Idling power 75 W 75 W 75 W Efficiency on nominal values Appr 85 appr 85 appr 85 Power factor on nominal values appr 0 93 appr 0 93 appr...

Page 4: ...source s power stage is a traditional half bridge where the intermediate circuit DC voltage is halved by working capacitors C2 and C3 IGBT transistors work as power switches When both IGBTs are non co...

Page 5: ...pens the electromagnetic disturbances conducting to the net EMI Varistors 550 V form an overvoltage protection against low energy voltage spikes Note Filter card Z004 and varistors are mounted before...

Page 6: ...t voltage The primary choke L001 limits the in rush current during switching and filters the DC voltage together with the smoothing capacitors Smoothing capacitors 2 x 25 F 700 VDC Work capacitors 350...

Page 7: ...the main transformer T001 Inverter s power adjustment is based on pulse width modulation PWM RC protections ease the stress on the semiconductors KEMPPI WELDFORCETM 5500 The chokes LL301 and LL302 of...

Page 8: ...ened by secondary choke L002 The secondary circuit current is measured by a shunt resistor The shunt s voltage is amplified by shunt amplifier A001 2 and taken to control card A001 s PWM adjuster Cont...

Page 9: ...e connectors X006 and X007 The cooling unit KWU 10 is connected to connectors X010 and X011 KPS 4500 KPS 5500 The control card A001 is similar in all Kemppi WELDFORCETM power sources The machine size...

Page 10: ...s switched on A faulty primary circuit semiconductor Check the semiconductors on the primary side The power source doesn t reach maximum power The net fuses has blown A faulty supply cable A faulty pr...

Page 11: ...ng X7 1 5 6 1 MIG wire feeder is other than KWF MIG wire feeder is KWF 2 2 Scratch TIG enabled Scratch TIG disabled 3 3 OCV is approx 65 V OCV approx 16 V VRD 4 4 Not in use Factory setting 5 Not in u...

Page 12: ...04 and auxiliary transformer T002 H3 LED SERIAL COMMUNICATION while the LED is on it indicates the presence of serial communication If the H2 is on but H3 is off most likely there is something wrong w...

Page 13: ...IGBT gate pulse a a The gate pulse on values 10A 14 5V MIG meas point a 10V 20 s DIV a The gate pulse on values 450A 36 5V MIG meas point a 10V 20 s DIV a Control cardi A001 13...

Page 14: ...Voltage over the lower IGBT b Voltage over the lower IGBT on values 10A 14 5V MIG meas point b 100V 20 s DIV b b Voltage over the lower IGBT on values 450A 36 5V MIG meas point b 100V 20 s DIV 14...

Page 15: ...he secondary diode cards c Voltage after the secondary diode cards on values 10A 14 5V MIG measuring point c 20V 20 s DIV c c Voltage after the diode cards on values 450A 36 5V MIG measuring point c 2...

Page 16: ...c Voltage on connector X010 between pins 2 6 measuring point d a Pump motor ON b Pump motor OFF c Pump motor continous run selected e e e e a b c Voltage on connector X010 between pins 1 6 measuring...

Page 17: ...pacitors Working capacitors Secondary unit Diode card Fans Main transformer T001 Shunt resistor R001 Auxiliary transformer T002 Control card A001 Filter Structure Filter card Z003 Commutation unit L00...

Page 18: ...Notes...

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