Service manual - Rapid Welding and Industrial Supplies Ltd
Contents
1. ee J5psmjc nw 0 3 W 1 3 a 2 An um Lx x 0 E Lx lx E xm Lu lx E 81 Sl Bl 5 H i zim Td 2 3 0 ZAAL 3 i AA 7 k JD di 0 m 8 nS F 7 Apud 385 214 ek A f te walle un 8 LES Jld 7 5 i p LA z uuc Z amp B us a 5 ey EL E MU EE m vHHV l Bapz a z fur EI ADAJ WEGE BBH B 8 z001 Y LA ZUR EBB Zu Lage IDS do cc eee B 4 E e 0 BM 288 09 7 3 PAHOA TWA stow FLW Lara Lut Pal ircuit diagram In CIFCUI Ma General The machine may be repaired only by an authorized and licensed technician or workshop First do a visual check to find the possible loose connectors broken wires or signs of overheating 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 Net fuses or supply cable Check the net fuses and supply cable power condition Main transformer 001 or secondary siode card Z002 Check the main transfor2. 19 The Joy of Welding Wire feed speed minimum and maximum adjustments X1 F1 6 3 AT R32 Min R21 Max After replacing control card A002 or feed motor M 001 the wf speed has to be checked and adjusted as follows 1 From panel choose synergic curve 00 2 Connect the power source to a load bank 3 Set wf speed to 18 m min 4 Check the actual speed and if necessary adjust by trimmer R21 5 From panel set the speed to 1 m min 6 Check the actual speed and if necessary adjust it by trimmer 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 synergic curve 00 2 Set wf speed to 18 m min 3 Enter the setup and adjust parameter CSL value to syn 4 When syn is plinking you can see the creep start value in case of welding value 18 m min the actual value will be 12m m 5 Measure fed wire length and if necessary adjust by trimmer R21 6 From panel set the speed to 1 m min also creep start value will be 1m min 7 Measure fed wire and if necessary adjust it by trimmer R32 8 Re check maximum and minimum 20 The Joy of Welding Panel testing KaKEMPPI The Joy of Welding m min mm eM t Panel program version Power source program version a d 05 GAS TEST ch remote C 3 W000373 Panel s
3. Service manual Ver 1 2 KEMPACT PULSE 3000 Contents Technical data ern 3 S witches and connectors eene 4 Palel uorum MEC VERMES ee S ynergic 01117768 e eene nns 5 5 KU Le 6 VILI 6 Main circuit sees 7 Main circuit diagram sss 8 Troubleshooting diagram 9 Main circuit diagram Z001 Functions 01011661018 10 OU 11 12 Main transformer 1001 primary voltage 11 12 Secondary diode card Z002 Functions connectors sss sess 13 T M 13 14 Voltage after the secondary diode card Z002 14 15 Control card A001 Functions connectors eeeeeee 16 17 IB M 17 IGBT 2e 011581 cocci eter 18 Control card A002 Functions connectors s sess ss 19 vU e E E 19 Wf speed min and max adjustments 20 Panel Parc UE l Wf motor current measurin g 2 lv mE M 2 CECI M 22 IGB 65110185 23 IGBT replacing sen 24 NOS E
4. Setup EAKEMPP The Joy of Welding Last welding value a M LA DYNAMICS GAS TEST ch remote CE Synergic curve selection Extra info of Selecto 5 channels synergic curve Material group Wire diameter Material type number Gas type Synergic curves o n A A Norma MG o an A A o x X s 08 S930 316 A 2 CO X x 52 09 ssa0 36 _ Ar 2 CO ASi 2 ASi 2 o x X ct 0 3 Magn LX X Fi 08 Fe a gt lt Oo x x F2 og Fe A 25 OOD X Oox Fe Ox to Fe 5 O x FA 140 Metalcore wire Ar 25 C0 The Joy of Welding SETUP functions The SETUP is entered by pressing the setup button for 10 seconds n gt Parameter selection Parameter adjustment SYNERGIC PRG 8 Adjustable parameter Adj range Quanti Post gas ime Pegsime 2 5 Hot Start level 2T Hot Start duration 02 G Hot H2t 5 CFS 5 s 10m min 5 n dFr DA E Crater fill end level Crater fill time angle 1 Creep start starting level Creep starttime angle 085 0 04 5 Omi E N Doublepulse freq 14 E o7 08 Double pulse Wf soeed amplitude ES MEN E Oo 42 Ignition pulse St PoC Pulse top current Post curre
5. 25 The Joy of Welding technical data Supply voltage 3 400 V 2159 50 60 Hz Loadability 40 ED 250 A 26 5 V 12 kVA connection power 60 ED 207 A 24 V 10 kVA 100 ED 160A 22V 7 5 kVA Power TT Filler wires 0 6 1 0 mm 0 9 1 2 mm 0 9 1 2 mm 0 8 1 0 mm Dimension weight L580 x W280 x H440 22 kg WEMPACT The Joy of Welding Switches and connectors Optical tachometer Wf motor Pressure adjustment screw Feed rolls Gear wheel 18 24 m min Minus Return current connector Plus Euro connector Panel Overheat protection sign Net voltage over undervoltage sign On off signal lamp EZKEMPPI Adjustable parameter selection mON 7e I Wf speed 2T 4T tmethod selection n Voltage Setup long press A nnlla Are engin 1 MIG SYNERGIC PRG Plate thickness current display selection quick setup Process selection Wire inch Double pulse 2 Z CH 8 1 Pulse MIG Chosen parameter adjustment 1 MIG S SAVE Y DYNAMICS PNE TEST Koei me Local remote control C 3 W000373 PU LSE Aux functions selection Crater fill Hot Start Spot timer Memory channels 100 Dynamics Gas test The Joy of Welding Panel Wf speed Plate thickness i 1 Voltage welding current display 0 CUVE Synergic curve material group Selected parameter s value display Jumper number Setup Jumper name
6. BmV Ww PTC 598 82 choke 1 i an can iy 407 i 1 Y1 The secondary diode card Z002 has these operational blocks Secondary rectify ing Machine size coding Overvoltage protections Dampening circuits Secondary diode card Z002 layout EX 4 ET b QQ ya lt s 29532521 cew uox O ue uw 24493 29797 Secondary diode card Z002 layout Varistor 2 x175 V Fast diode 10 x 60 Voltage after the secondary diode card 2 COGS t 4n7 Y1 4 7 Y1 Secondary R7 ROO PTC Secondary Coo 1 i 1 i 1 1 choke 1 14 The Joy of Welding Voltage after the secondary diode card 2 Eh Tasasuuntaajan j lkeen SOA 16 sv Ioj xl Input O Tu mJ rrr EAMA Tl TEL X E LLL BL LEL GE ed Lat M Voltage after the secondary diode card with values 250 A 26 5 V Synergic curve 00 meas point b 15 The ion of Welding Control card A001 functions connectors The control card A001 has these operational blocks e RENESAS M 16C26 microcontroller Panel connection e Service bus programmin Aux voltages developement monitoring Power stage on off control Power stage PWM control Primary current measuring Secondary current measuring e Secondary voltage measuring Dynamics gnition pulse Post Current Ov
7. erheat protection Net overvoltage watch e DC Iink charging control Welding gun connection Wire feed control e Solenoid valve control Connectors MEato chomein __ The Joy of Welding D p p gt O O 2 D BRO D LXIS _ xu X21 _ X2 LXI3 X4 _ LXI2S _ xu XL B rk 8 rik v B E eg E nu TOU pm bike rds 3 tea emg tra zo 2 tem kx o du a 9 3 m 0 gt 0 9 j 17 H3 H6 Gate pulses 5V 15V H2 H1 X16 X15 X14 X8 H1 X6 X5 X4 X3 X5 X7 H2 H4 X10 H3 H5 X12 Control card A001 layout un 5 E 2 Q Control card A001 connectors 18 a 0 3 Ll 0 09 9 j 10 us Div ex Eg cix Ea cix Gal cix ra olx zm olx za gx ag ex a L00V ia Ww 7 Ed 1 E a a x m wo m Gate pulse in idling measuring point c Hilapulssi IGBT gate pulses Control card A002 functions connections Control card A002 has these operational blocks e Wf motor control PWM Power supply filtering Overvoltage protection WE Current ote e CC ONE X1 12 Main transformer aux coil Control card A002 layout X1 F1 6 3 AT D2 b cd R32 Min R21 Max
8. mall 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 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 24 The Joy of Welding Notes
9. mer TOOI s ferrites and secondary diode card The Joy of Welding Main circuit card 7001 functions and connectors Main circuit card Z001 includes the following operational blocks Overvoltage protection e EMI filter Primary rectifier DC link charging DC voltage filtering Full bridge IGBT module Main circuit card 2001 layout x1 X3 X4 X5 X6 X7 X8 X9 X10 X11 X19 X20 10 The Joy of Welding Main circuit card 2001 layout Smoothing capacitors DC link charging resistor and relay 4 x 470 F 450 V Main switch EMI filter Full bridge IGBT Primary rectifier 3 x Main transformer T001 primary voltage Fe coil rings Wire feeding power supply Main transformer 1 a transformationratio 1 10 The Joy of Welding Main transformer 001 primary voltage Pasmuuntajan ensi 44 8 us 10 uz Main transformer T001 primary voltage with values 50 A 16 5 V Synergic curve 00 meas point a Pasmuunt ian ens 2504 26 5Y x inn j i 2 5 x Input PA Bn TTT TT ZENMERBSENEE nmNMESENE LM Main transformer T001 primary voltage with values 250 A 26 5 V Synergic curve 00 meas point a 12 The Joy of Welding The Joy of Welding 2 9 Secondary diode card 2002 functions connectors je m 3 iini T HOCH JARA
10. nt time Arc length adj range Calibration o 10 oon 000 st gt gt om sm C wgn s e o ow Guncontollraubmeicdetecim 54 GE On oo _ Fadonsetinpsecal 99 FAC OFF OfPanAl Error codes Em3 Net overvoltage BAIE oes Power source overheated ErrS j Coolingunithas stopped welding unit has stopped welding Ere Power source output voltage is has risen gt 80 Vdc EM PMT gun overheated or RMT 10 installed and PMT gun in FU position EBr 4 Wf motor overload current gt 4 5 A 5 s The Joy of Welding Main circuit P d d d Er AN Al dl mrt i TET Be IX ZX IN RAZ v2 4 IN Po E HK GPs C6 NE BH ep S X1 X2 Second ary circuit The Joy of Welding a 0 3 Ll 0 09 9 j Lx E E lx X IX amp IX IX LE LX Ix Lx Ix i aad uo Jj anza E E Lax Sy 5 uBgi 7 y 8 8 ABEZ rca EQUES unm uum Wg 21 7 guug ui d WWG 1 LL f 6 g aar 8 AEE I sit aage 87 1 oway ny 2 Te Hu 5 2 MIU g g ZW g 88g y3eduasay 7 Si 0 I 7 a B oq IB es I O oe g b LH s ye vy vey IE ds
11. witches LEDs and displays can be tested After turning the power source on 3 sec all LEDs and displays should be lighted and after pressing any of the buttons the program versions should be shown on the panel Wire feed motor current measuring KAKEMPPI The Joy of Welding Wire feed motor current a YY a DYNAMICS CAS TEST ch remote C W000373 By pressing the Wire Inch button and plate thickness button simultaneously the motor 1 current will be seen on the right side of the display Panel layout KaKEMPPI X1 Flat cable panel gt power source X10 Programming connector panel X11 Programming connector power source a of DYNAMICS GAS TEST ch remote The Joy of Welding Structure A002 Control card P001 Panel Y001 Solenoid valve A001 Control card M002 Fan S001 R001 Main switch Shunt L002 Z002 Z001 Sec choke Secondary diode card Main circuit card 22 The Joy of Welding IGBT testing IGBT module can be tested in two phases with an IGBT tester as seen in picture below E2 l C1 3 x1 C1 X21G3 B1 4 X3 G4 G3 X21 X4 X5 5 X22 E X6 G2 amp C2E1M C1 X7 B2 6 9 2 8 61 X G2 X4 E XI E3 X7 El X1 C2E1 x x2 m G4 B2 6 gt x G2 X4 FA X5 E2 23 The Joy of Welding IGBT replacement IGBT mounting onto the heat sink The installation surfaces must be clean even very s
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