Service manual Fitweld 300 - Rapid Welding and Industrial Supplies
Contents
1. b m HESS m um ey AW ere Cha P A3 cT VETE E acr n hi Current transformer Primary rectifier t HAN IGBT module EMC filtering Jumpers X26 clos X28 clos X29 clos Gate transformers default settings X25 open ed generator compensation off X27 open ed ed X32 open The Joy of Welding Main circuit card 2001 Measurement points DC link voltage with Kemppi multipower digital multimeter Auxiliary 1 Feed 22 VAC to auxiliary transformers secondary transformers connector from Kemppi multipower connector secondary must be connected connector 2 Measure value from DC link test points by digital multimeter L1 L2 and L3 DC Link DC Link Value 500 VDC or more 3 Measure secondary voltage start signal needed Value 30VDC or more Primary rectifier Digital multimeter diode test 5 e 1 Red test probe L1 L2 and L3 one at the ge time dl wu x Black test probe DC link plus Jr aee ux Value 0 3 0 5 VDC diodes ok Om 2 Red test probe DC link plus ome i Black test probe L1 L2 and L3 one at the EE e e ANM gu Fit time el Value No value diodes ok I prn 3 Red test probe L1 L2 and L3 one at the tes m y eu w MA s Black test probe DC link minus TE ee Value No value gt diodes ok gt E AE in2. epu The Joy of Welding Technical data Supply voltage voltage V ne 50 60 Hz Rated power Max 11 kVA Load capacity 40 C 300 A 29 V 220 A125 V 180 A 23 V 140 A121 V Welding range range 20 A 20A4 11V 300A732V 11 V 300A 32V Connection cable fuse pee 4 x 1 5 mm 5 m 10 A delayed Open circuit Open circuit voltage Pa e M Spolmao max External dimensions L x W x H 457 x 226 x 339 mm The device may be repaired only by a person legally authorized perform electric work The Joy of Welding User interface Front Plate 1 Welding voltage adjustment 2 Wire feeding adjustment 3 ON signal lamp 4 Overheat protection lamp 5 No gas warning lamp 6 Euro connector p 4 lt e lt e lt d Se Back Plate T Gas connector 6 Main switch 9 Ground cable connector Spool room 10 2T no gas 2T 4T switch 11 Gas flow adjustment 12 Spool room light 13 Polarity selection et VKEMPPI The Joy of Welding Construction Gas flow A001 adjustment Gas pressure Gas valve switch P001 Wire feeder motor 2002 Cooling fans Tip If machines cover plate screws thread fails you could change PT screws diameter to 5 5mm 6mm Note Protective earth conductivity test must be performed at earth points on both the front and back plates 4 gy V KEMPPI
3. The Joy of Welding c Bg T5 Sd3 o c 3 3 gt tuolt 44012 J rHOWIWA MIJA WD ILOS m 1 BBH BZ PI9M 1 4 IBABA 0 5 EBBS 7 Bax OS e FASS jur Dx OQ 1 z ZNYJ INYJ n E o 46 urqea E el Luvs m m E ON TM di ie od _ x E cdi 1 to yuo zBBH g 1 1 L ay d i i X o EBDX LAGH lt J 1 a Zag i BRI me ON 5 5 0 i IBAN LNO I vBa INDI 7 i gz ino n az 1ino S O 150d SYI 1504 NE ino l1HvlS JM ino LHYLS E i 121 FT NO NO Hamad i i LHS Ino LHY1lS i daH NI LHYwIS NI LHYvlS f 1HVIS dA 2 E LINY TYNHILNI INE LIGA H3A 0 LTDA H3AQ0 i 5 i H3 0 dM3L 1 iH aa IA quss r e 5 SO LIOA E d39vi D i abuey3 INE Aejdeip E
4. 1Snr wv NAT 5 NAG c 1 jeuorido IPAPZ IPAPZ i ry p p 1 SOINYNAG l 440 18994 SUZ a i 4 deaws bas zx Pee cumugu r K ino ua u p 44875 qv JASI NOILVvVSN3dMO2 HOLvHaNa3s dwos ua z gx i taal IBz1H NEN i 1 9 x mc Auepuosas IYASI ww p 1 Io 1 YABI I MGM eo a ee co hla ee P ILL 2007 IV ABE ela 3 428g l abueg rx i y Aaron i 59 ONS i EBz1d ou 239 wo 3 Us T 2 1997 j 9 aumg d T n IBEX Laat gt LAOS J J J rJ JD 2npup3 se quis rl VDRH 558W Main circuit card Z001 Functions and components EMC filtering Primary rectifier and DC link charging PTC H bridge frequency 27kHz Gate transformers and gate drivers Auxiliary voltage 15VDC Over voltage sensing from DC link Two stage fan start PTC protection alerts signals comes from the main transformer and the secondary choke 15VDC aux voltage indicator LED X25 _ X27 a d d 7 7 a vum LIES E F LIE i ok B THE T
5. test 1 or 4 are close to zero rectifier is values in tes 7 ifier time test probe L1 L2 and L3 one at the short circuited If value is no value circuit is open Value 0 3 0 5 VDC gt diodes ok P If values in test 2 or 3 are close to zero diodes are leaking VKEMPPI The Joy of Welding secondary rectifier Z002 Main components Middle point connected full wave rectifier Damping circuit reduces voltage stress of diodes Overvoltage varistors protect diodes from ignition sparks Common point Measurement points Secondary diodes 3 1 Measure diode branches one at the time 3 from transformer red test probe to common point black test probe Values 0 3 0 5 VDC A 2 Measure diode branches one at the time from common point red test probe to Diode branch transformer black test probe Resistor A i Value No value gt Resistor gt 3 Damping circuit resistors Resistor value must be 50 Diode branch B Qu w Quouu eu The Joy of Welding Wire feeder motor control card A001 Functions Wire motor power feeding from machine s secondary circuit by MOSFET half bridge Wire feed speed maximum adjustment by trimmer Spool room light in different small card NOTE When installing spare part card you have to check wire feeding speed maximum adjustment level Before installing tilt and detach spool room light card Tilt and detach Adjust
6. 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 between the components At first all M5 screws are tightened carefully to torque of 0 5 2 Nm after which the module can be tightened to the nominal torque of 3 Nm After a few minutes the screw torques are checked again to be 3 Nm Secondary diode unit As described above but screws are torx T 10 and tightening torque 1 2 Nm Diodes can be tighten right away to this torque 11 The Joy of Welding Notes 12 The Joy of Welding
7. ments e g Py mala Ta Eo qv m mee pe zii le 225 IE z 1 20 zb LE ie jo E PIE w Wire feed speed maximum 1 Adjust wire feed speed potentiometer t al maximum LEE d Tr 2 Feed wire 10 second by triggering the torch 3 Measure fed wire length 4 Should be 16 7 of 18m min 3m min f wire feed speed is offset adjust trimmer and repeat steps 2 4 The Joy of Welding Panel card P001 Functions Supply voltage 24VDC filtering Generating reference voltage 3 3VDC Voltage adjustment by potentiometer Wire feed adjustment by potentiometer Start signal throughput for optional usage Three leds On Overheat protection and No gas Gas pressure switch 002 Functions Prevent welding while gas pressure under adjusted level Adjusted to 1 bar as a default Not functioning in gasless wire mode Alert level adjustment Adjustment 1 Connect gas hose to gas connector 2 Adjust pressure to 1 bar 3 Adjust pressure switch alert level to 1 bar 10 The Joy of Welding Installation of semiconductors IGBT mounting onto the heat sink The installation surfaces must be clean even very small particles 0 050mm between the surfaces increase the gap between heat sink and module causing module overheating and possibly destruction Heat transfer paste is spread as an even layer about 0
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