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Service manual

Ver. 1.0

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Содержание WELDFORCE KPS 3500

Страница 1: ...Service manual Ver 1 0...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 18: ...Notes...

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