technical service manual for kempoweld
Contents
1. HA Johdinvar it Ledningsfarger Conductor colours Leitungsfarbe 1 5500W ru brun brown braun si bla blue blau mu svart black schwarz 5002 pu red red rot 49 gul yellow gelb 2 1 vi gren green gr n K14 ue K13 ha gra grey grau 4 3 m I 4 kevi gul yellow grun r 6 Ken 48 4 5 B L gr n green gelh 1 1 2 Al A2 25 48 a a VUK95 lt 2 n IA U 5081 5 T B 4 ET i 52. 3145150 XEMPOVELD4000 6000V 12250 VARAOSAT SPARE PARTS RESERVDELAR ERSATZTEILE RESERVE DELER ONDERDELEN RESERVEDELE PIEGES DETACHEES 59002 5 001 8 188 SRaa4 Jd 17001 1 1 2 012 gt 881 VARAOSAT SPARE PARTS 1921840 RESERVDELAR ERSATZTEILE KEMPOWELD4000 4000W RESERVE DELER ONDERDELEN V215304 RESERVEDELE PIECES DETACHEES 5 210 5 228 5 2 5 15001 25001 5 140 6 140 15002 25002 35002 45002 3145140 KEMPOWELD 5500W 2 VARAOSAT SPARE PARTS RESERVDELAR ERSATZTEILE RESERVE DELER ONDERDELEN RESERVEDELE PIECES DETACHEES G I KEMPE KEMPOVELD 5500 gag 2068978 VARAOSAT SPARE PARTS RESERVDELAR ERSATZTEILE Vo 15501 RESERVE DELER ONDERDELEN RESERVEDELE PIECES DETACHEES SIMACO PUMP MOTOR O 01 94
3. e __ Faa 2 S H 005 VARAOSAT SPARE PARTS RESERVDELAR ERSATZTELLE RESERVE DELER ONDERDELEN RESERVEDELE PLECES DETACHEES qu The Jou 8 3144540 RE VARAOSAT SPARE PARTS 1921270 RESERVDELAR ERSATZTEILE RESERVE DELER ONDERDELEN RESERVEDELE PIECES DETACHEES 3144540 VARAOSAT SPARE PARTS RESERVDELAR ERSATZTEILE RESERVE DELER ONDERDELEN RESERVEDELE PIECES DETACHEES 238 229 178 050 Ka KEMEPPI The Joy of 20655794 RE 4 0 VARAOSAT SPARE PART
4. 7 4 4 C D 14 2 n n 47 Zon 2 ul 25 w 02 2 5 45 500 K12 no 4 1 3 21111111 2 5 m N x 5002 5003 SALZER K amp N SALZER L1 2 R 1 1 L2 9 5 5 3 L3 14 T 14 17 ul 3 U 2 2 V1 5 5 4 wi 15 w 13 5 U2 7 x B v2 12 Y 7 w2 B 2 4 12 14 16 1B 20 22 24 KEMPOWELD 4000 Johdinvarit Conductor colours Ledningsfarger Leitungsfarbe ru brun brown braun si bla blue blau mu svart black schwarz pu red red rot ke gul yellow gelb vi gren green grun ha gra grey grau kevi gul yellow grun gron green gelb 5001 5 58 2 eel Rea om N AN R222 5 1 5 en N 5a 2 T M E 3 3 19 178 li i PET al 1 07 1 21 T T T TTT 2 1 o v m n N N N zo NI Z VE e 23 22 2 4 D 25
5. I a lt o a I 001875 138950 4279940 2062900 144940 144950 1028360 1028370 1028350 592126 1 370162 0 52 373216 0 7 4278740 1 373215 0 3 4279930 4279920 568956 568957 761302 885031 310 320 885032 310 7 51 RED 3142290 320 CIRCUIT DIAGRAM KEMPOWELD 3200W 1 KEMPOWELD 4000 4000W 7 3 2000 V215304 3145140 1921840 no Part Description Pa 4287420 16002 PARALLELDIODE KEMPOWELD 1 775729 775730 H002 SIGNAL LAMP GREEN 138540 544214 4287840 4266150 771530 4191441 2001 PROTECTION 1 _ 547105 001873 1 I FKEMPOWELD 4000W 230 aa SWITCH 32A O Y D K60 10 D22 5 2 4000 40 44 400 504 2 764160 SWITCH 32 D K60 10 D22 5 J KEMPOWELD4000 400V 764130 76051501 76052101 2066170 KEMPOWELD4000W X 230400 144940 144950 5 150 1028360 5 160 COVER PLATE KWELD 3200W 4000W 1028340 5 170 1028350 5 180 592126 5 190 5 5 5 1 370162 200 0 52 373216 210 0 7 4278740 220 1 373215 0 3 4279930 4279920 5 250 568956 568957 581007 5 280 761302 885031 9885032 5 310 STICKER RED KEMPOWELD 4000 4000W 7 3 2000 V215304 3145140 1921840 Orderno _ Pat Description 9540410 5 002 10 6761221 63004 FLIP FLOP SWITCH 1 9761622
6. KEMPPI KES 54 002 ps VUK 50 2 7 C001 o Ix 1 T T 5002 s MD P N pi 46 TNI 410 XW101 2 412 48 47 45 411 gx exl 38 A001 38 x m RW102 37 16 NAP 4 NAUHA KAAPELI LISATOI MINTA YKSIKKO Na Ny NAN XT xT xT x AN ZA yo X32 lt e 33 x ae x34 lt gt ee KOKO VALM OHJE WIRE 400 m m 8 LN TARK TARRA 2 VUK 7 2 22 C Stt h poma sh Hl T 1 q S002 3 XW102 2 2 T 1 1 fr SJ XW101 N 9 I 241 S A 1 37 44 L J ut iD m N wo 55 N N 16 4 NAUHA Y Y KAAPELI Le XE P we KMW TIMER B i o on ov N N m m SETET 1 1 m AM lt 2 9 3 4 51 52 au TS gt a 27 E TB 4T 10 CH SYNKRONOINTIK 1 3 X25 Z gt KEMP
7. 2 C m x NAUHA KAAPELI MSDI PIIRT TARK TARRA EN VALM OHJE 5 54 002 3139050B 25 01 2000 Johdinvar it Conductor colours Ledningsfarger Leitungsfarbe brun brown braun si bla blue blau pane Aes mu svart black schwarz 14 23 v 4 2 pu red red rot 1 gul yellow gelb 257 147 LI K12 2 55 45 4 Li 1 m 2 1 6 vi gren green grun L2 O 2 5 149 12 K14 L B ha gra grey grau 4 1 3 I ia kevi gul llow grun m 2 5 14 L3 14 N 2 59 148 D al 5 L gr n green gelb 2 5714 1 14 11 2 A2 IB bs 18 2 5 47 17 24 i 2 58 n 1 51 LA 2 4 5 5 L Ld SOBI 5 B do Rag A 11 23 1 2 18 T 6 d 2 5 47 1 i 1B 8082 Ys m 5 JE 5 L 4 1 4 am 2 5 47 17 20 A 22 1 2 3 2 24 k 5003 1 178 a De 4 Uu 5
8. 5 r 1 PTI 5 x m o gp 1 3 _ _ m 23 De OR MI b B S ne 2 2 1 A 12 mv DS dl 2 4 42 eo 24 238v 29 C PL 28 D L 22 2 21 vihr M Sri z PL WE F en 27 227 SANA EN 5004 5 10227217 k H a no i __ ie 5001 5002 5003 Ga SALZER K amp N SALZER K amp N T IBNAP KANE dd PU 2 5 2 X212 2 12 9 5 5 8 1B 7 sr pal x 5 KAAPELI L3 114 T 4 17 18 ui 2 2 1 nd x vil V 5 SE 51101 5 w 15 7 u 2 5 tar i U2 7 x B 3 KEVLL 14 vz 12 Y 7 Y MU EX se W B Z 4 12 13 3 B 2 2 2 3 14 15 caer N N N L 7 BUF 1 11 2 2 12 Ii 18 17 3 51 PL O 2 2 I O 2a 21 SPECK 2 Y 22 23 H803 pun 24 wes 13 213 m M 2 8 PL X 1 ago Y i HBB4 i x N N N N 2 14 gt e 26 MU 2 SUR T Y PIRT LN TARK 60 388821 t D OF SIMACO Q 5005 4000W KES 54 002 3139 6 A
9. B 5 XBBI KEMPPI KEMPOWELD 250 VALM OHJE 5 54 002 LN 991006 3144210 Johdinvar it Conductor colours Ledningsfarger Leitungsfarbe ru brun brown braun ye llow green 5092 5003 SALZER K amp N z Y kelt 77 5 M 2 18 al XBO2 B EN ii KAN LN KEMPPI KEMPOWELD En Lo o 3200 2 313280 4 0B MINE Le Ke s s 3200W Johdinvar it Conductor colours Ledningsfarger Leitungsfarbe brun brown braun si bla blue blau x u2 d mu svart black schwarz 1 pu rod red rot LU og K2 N x21 ex ke gul yellow gelb L2 K14 X24 vi
10. TECHNICAL SERVICE MANUAL FOR KEMPOWELD MACHINES TECHNICAL SERVICE MANUAL FOR KEMPOWELD GENERAL MAINTENANCE OF KEMPOWELD Maintenance of Kempoweld power source will normally consist of general cleaning of unit with soft brush and vacuum cleaner and checking of wearing for parts like switches connectors potentiometers and fuses NOTE If you use compressed air for cleaning there is a risk that dirt is packed even more tightly into gaps of connectors or components so be carefull with those parts Maintenance of the wire feeder and mig gun will normally consist of general cleaning and change of consumable parts like contact tube contact tip contact tip adapter gas nozzle wire conduit feeding rolls guide tubes and gear wheel The number of machines in will determine to what extend consumable and spare parts will be stocked WARNING Watch out for the mains voltage Disconnect the power source from mains voltage before removing cover plates or any testing or measurement and before troubleshooting look for signs of over heating fractures and damages from internal components and power semiconductors TROUBLESHOOTING CHART TROUBLE CAUSE REMEDY The KEMPOWELD won t start at all any of the auxiliary devices won t start The signal lamps of machine are not switched on The wire feeding unit 200 400 won t work Blown fuse in mains supply voltage Faulty mains cable Broken main switch Faulty auxiliary
11. 16 5 18 ON 49 17 22 1 Y 24 5803 5 3 DNI 4 c 170 T Ese g L L 3 1 T T T TT T T T 26v 33 vo 3 4 x o m Dr x 32 g an iW et 22 li 12 5 4 1 BA 223 v v 42 x 25 21 2 2 22 14841 527 er 2 4 H 2 v m E m N x x x3 q 3d Sd Foa2 d 1 5002 5003 NAUHA K amp N SALZER K amp N KAAPELI 5 R 5 5 8 5884 14 17 18 u 2 2 1 2 T T 5 ML SEMI MSD mit tar il En w 13 7 MU za m 27 gt x 8 3 BU N L Y 7 18 8 Kimi z 4 12 13 14 15 36 2d 22 15 SPECK 18 17 5 Me 21 22 23 2 5 ta a 1 KEVI KEVI x MU N N 2 14 gt ly 51 1 PIRT LN 980518 te N KEMPPI KEMPOWELD OF SIMACO 5 5 3142130 KES 54 82 16 NAP NAUHA KAAPELI LISATOI MINTA YKSIKK NANAN N N x KMW TIMER X24 x 5 AAA A AAA SYNKRONOINTIK LN TARK TARRA 991006 ez 3144220 K200 WIRE 200
12. 59005 PRESSURESWTCH Jf Z KEMPOWELD4000 230400 028120 6160 1 1 20707860 6 170 KEMPOWELD 4000 1 3141290 67002 J AUXIL TRANSFORMER Jf 7 KEMPOWELD 5500W 6 08 2001 V216501 2068970 1921690 Order no Part Description Description 4279480 A001 CONTROL CARD A001 KWELD3200 4000W 4279500 A002 CONTROL CARD A002 KWELD 4000W 4287250 14003 PROTECTION CARD K WELD 5500W 755223 C002 CAPACITOR 8UF 450V AC 755177 C001 CAPACITOR 4UF 400VAC 772551 FOO1 FUSE BOX NUT 772551 F002 FUSE BOX NUT L M002 gt I o N 0 750175 G001 RECTIFICATIONUNIT 2 4287420 775729 H001 SIGNALLAMP YELLOW 0 2 775730 002 SIGNALLAMPGREEN 775731 HO03 SIGNAL LAMP RED 0 2 775729 H004 SIGNAL LAMP YELLOW Cd 764160 CONTACTOR 142030 544262 540410 M002 PUMP MOTR j 138320 COMB SIMACO 4286970 4286540 4282710 760615 SWITCH 32 O Y D 60 10 D22 5 771540 6185666 1027740 SIDE PLATE RIGHT KWELD 5500W 1027750 1027710 1027730 FRONT PLATE KEMPOWELD 5500W 1027770 REAR PLATE KEMPOWELD 5500W 001873 po O O o 001875 592158 4281090 090 HANDLEPIPE KMIG4000 8200 592126 547150 547711 1027050 1026960 138950 373215 568903 4286530 4279930 540415 551058 568956 568938 568957 BRANCH CONNECTOR 2060 1 4
13. and control card A001 is loose or cut Faulty KMW timer unit Check and change the KMW timer unit See also potentiometers from PICTURE 3 The water circulation stops after 5 s Low cooling water volume Check the water and fill it if needed of welding Air bubbles or leakages in cooling Follow the instructions of System Kempoweld Operation Instructions Operation Disturbances Faulty pressure switch Check change the pressure switch TECHNICAL SERVICE MANUAL FOR KEMPOWELD TABLE 1 CONNECTORS AND CONTROL LINES KEMPOWELD CONNECTORS X006 AND K200 400 XW101 XW101 X006 K200 400 KEPOWELD VALUE A001 A001 X3 1 X8 3 30 VAC 3 8 2 1 30 37 2 11 START PICTURE 1 KMW SYNC CONNECTION i HC start IN TECHNICAL SERVICE MANUAL FOR KEMPOWELD PICTURE 2 A004 MP SYNC CONTROL CARD JU CX JE X1 X2 X3 A004 PICTURE 3 PCB OF K400 TIMER UNIT R15 R11 X1 Potentiometers R11 Gas post flow R15 Cycle time R 19 Pause time TECHNICAL SERVICE MANUAL FOR KEMPOWELD PICTURE 4 A001 PCB OF K400 V2 X6 R24 X4 Potentiometer R24 Adjustment of wire feed speed TECHNICAL SERVICE MANUAL FOR KEMPOWELD A001 POWER SOURCE 4 12 Vover the ca
14. 581006 4280650 3142130 _ CIRCUITDIAGRAM _____KEMPOWELD 55009 5592136 Z frr 9761302 PROTECHON SWITCHESLEVER 2 9772523 FUSE4ADELAYED so 9772526 FUSESADELAYD 5 2 1 I a oo AJo N 6185666 1027740 027750 1027717 1027730 1027770 4281090 027050 1026960 4286530 4279930 4280650 WIRE 200 7 11 2002 V217201 3144540 1921770 Description Description 4279550 001 CARD WIRE 1 4280180 C001 CAPACITOR 0 1 UF 250V S001 9754156 754141 POTENTIOMETER 10 KOHM CERMET 761375 5001 770450 770117 770458 9770460 I 206653001 STICKER KEMPOWELD WIRE 170 WIRE FEED STICKER WIRE WIRE 1026870 111 ACCESSORIES FF 6219200 1 020 UNIT KMW TIMER I WIRE 400 7 11 2002 V217401 2066790 1921560 Description Description 4279550 A001 CARD WIRE KEMPOMAT 1 4280180 C001 CAPACITOR 0 1 UF 250V S001 754156 754141 POTENTIOMETER 10 KOHM CERMET 761375 sor 770450 770117 770458 770460 i 139410 139100 4296210 0 160 4279770 0 170 WIRE FEED STICKER WIRE 4280040 4280050 4296870 STICKER KMW SYNC 1026870 1026880 138810 116880 1 55 j WIRE 550 7 11 2002 V217501 2069120 1921
15. transformer T002 or bad connection in connector X9 400V or OV Blown fuse F001 8A Faulty connection in control lines Blown fuse F001 8A Broken PCB Check all three supply voltage phases check fuses Check mains voltage from terminal block X001 repair cable if needed Check the main supply voltage before and after main switch change switch if needed Check transformer repair transformer connection or change if needed Check fuse and change if needed See TABLE FOR CONTROL LINES table 1 Check change fuse F001 See TROUBLE SHOOTING FOR PCBs appendix 1 TECHNICAL SERVICE MANUAL FOR KEMPOWELD TROUBLESHOOTING CHART TROUBLE The cooling unit don t start or pilot lamp Hw3 lacking water pressure is iluminated The solenoid valve YOO1 don t work Wire feeding motor don t work Welding quality is bad arc is not stable there are lot of spatters bad arc start not enough arc voltage Blown fuse F002 2A Auxiliary transformer 002 Pressure switch S005 5uF capacitor C001 Broken PCB Faulty solenoid valve or PCB A001 Blown fuse F001 8A The control cable between feeder and power souce is broken or it is not properly tightened Faulty motor or PCB A001in K200 400 Broken PCB One phase is missing Faulty main transformer T001 Faulty main switch S001 or contactor K001 Shielding gas is missing Gas hose of the gun is leaking or connection is
16. 701 Description Description 4279550 A001 CARD WIRE KEMPOMAT 1 4280180 C001 CAPACITOR 0 1 UF 250V S001 lt gt 754156 754141 POTENTIOMETER 10 KOHM CERMET 761375 5001 LEVERSWITCH 770450 770117 770458 770460 3142370 000 CIRCUITDIAGRAM 550 427040 060 PRESSSPRING PROMIG DOOR PLATE WIRE 400 550 9549064 1090 SLIDE LOCK 2066530 568911 139410 139100 4296210 STICKER KEMPOWELD WIRE 70 4279770 4280040 KEMPOWELD CONNEC WIRE 4280050 4296870 1026870 1026880 138810 1 ACCESSORIES 6219100 SYNCHRONIZAT UNIT KMWSYNC 1 3135870 PROMG 1 KEMPOWELD2501 VARAOSAT SPARE PARTS RESERVDELAR ERSATZTEILE RESERVE DELER ONDERDELEN RESERVEDELE PIECES DETACHEES 015 1902 aa 888 293 013 S le EMEP Ie VARAOSAT SPARE PARTS 19217680 RESERVDELAR ERSATZTEILE KEMPOWELDJ2 501 RESERVE DELER ONDERDELEN RESERVEDELE PIECES DETACHEES 3144530 KEMPOWELD3200 zu VARAOSAT SPARE PARTS RESERVDELAR ERSAT
17. E other occasional disturbances connector FOR CONTROL LINES table 1 Faulty switch in mig gun Check and change the switch if needed Loose start wire s in mig gun Check and tighten the start wire s inside the gun Machine is overheating because the Faulty fan or PCB A001 Check the 24 VDC voltage from fan fan don t start connector X2 12 and X2 13 if it is all right change the fan if it is not change the PCB See TROOUBLE SHOOTING FOR PCBs appendix 1 Wire feeding speed set value can t The set value potentiometer RW102 Check and change the 10KQ adjusted is faulty set value potentiometer RW102 if needed KMW sync is not working Faulty connection in connector X1 Check and repair connection according to PICTURE 1 If some other push pull gun than Wrong motor voltage Select correct jumper combination Binzel or Hulftegger is in use the gun there are two jumpers X1 and X2 is pulling to fast and the fine adjustment for voltage can made from MP SYNC PCB from MP SYNC control card See also PICTURE 2 MSD 1 meter unit don t work Ribbon cable between MSD 1 and Check and tighten the cable check control card A001 is loose or cut also the control voltage for MSD 1 from A001 X3 16 and X3 1 the value should be 12 V Faulty MSD 1 unit Check as mentioned above if it s all right chage the MSD 1 Occasional disturbances with KMW Ribbon cable between KMW timer Check and tighten the ribbon cable timer unit
18. PI K550 lt x21 5001 8 8 WIRE 550 LN TARRA 980515 KOKO VALM OHJE 5 54 002 314 2 7 7 KEMPOWELD 2501 7 2 2000 V211203 3144530 1921760 Order Pat Pc CONTROL CARD A001 KWELD3200 4000W 2 3141290 T002 AUXIL TRANSFORMER 771530 4191441 2070060 2070330 2070080 2070340 2070350 1026120 000 COOVERPLATE 3144210 CRCUITDAGRAM KEMPOWELD250I FRONT PLATE KEMPOWELD 2501 SIDE PLATE LEFT KEMPOWELD 2501 SIDE PLATE RIGHT KEMPOWELD 2501 KEMPOWELD 3200 7 3 2000 V215303 3145130 1921830 Order no Pat Description Pc 4266150 SHUNT RESISTOR 300A 60MV 761225 76052101 8002 25 1 2 2066190 141290 771530 4191441 ZG001 RC PROTECTION 2070060 UNDERCARRIAGE KEMPOMAT KEMPOWELD 2070820 RONT PLATE KEMPOWELD 3200 HE F 2070790 2070800 3001873 007 0 1 3001875 08 JINSULAT PLATE FOR 1 1028120 0 09 COVER PLATE KEMPOWELD 3139040 CIRCUTDIAGRAM KEMPOWELD3200 1 KEMPOWELD 3200W 7 3 2000 V216302 3145150 1921850 Order no Pc 712551 4287420 775729 H001 SIGNAL LAMP YELLOW 775731 775729 H004 SIGNAL LAMP YELLOW 764130 138510 544214 M001 COOLINGFAN 2800 3500 138320 540410 761221 1 761622 2066190 1 141290 2069250 001873 060 0 00
19. S 1921560 RESERVDELAR ERSATZTEILE RESERVE DELER ONDERDELEN V217401 RESERVEDELE PIECES DETACHEES 1 vegi 2881 2066790 WIRE 550 VARAOSAT SPARE PARTS RESERVDELAR ERSATZTEILE RESERVE DELER ONDERDELEN RESERVEDELE PLECES DETACHEES 228 Aa 128 Gaal 119 Welding 2869120 BE 5 5 VARAOSAT SPARE PARTS 1921781 RESERVDELAR ERSATZTEILE RESERVE DELER ONDERDELEN V2175 1 RESERVEDELE PIECES DETACHEES XW104 260 2 XN 1 1 2 XW103 2069120
20. ZTEILE RESERVE DELER ONDERDELEN RESERVEDELE PLECES DETACHEES kadi 815 082 003 e VARAOSAT SPARE PARTS 1921830 RESERVDELAR ERSATZTEILE 09200 RESERVE DELER ONDERDELEN 215303 RESERVEDELE PIECES DETACHEES 3145130 XEMPOWELD3200 VARAOSAT SPARE PARTS RESERVDELAR ERSATZTEILE RESERVE DELER ONDERDELEN RESERVEDELE PIECES DETACHEES 9 ow Cam VARAOSAT SPARE PARTS 1421850 KEMPOWELD3200 RESERVDELAR ERSATZTEILE RESERVE DELER ONDERDELEN V2 16302 RESERVEDELE PIECES DETACHEES 810 889 230
21. gron green grun 4 3 poi ha gra grey gr au K16 4 E89 er 5 5222 gul yellow grun 1 X23 gron green gelb EDS S 2 Al A2 4 Z C 5 x25 re X203 Goa A vuksa Cp im 2 4 Y en RABI 4 d 5883 CI m DOM 2 S 1 saat AP A raus gt EA en 4 4 fod C II vvv 2 1 0 HE m 5 12 1 U zu 16 178 18 28 22 24 1 2 d 4 7 T T T T T m m N a 1 1 as d 15 3 RU 1 3 23 lt 22 21 De C iz v BA D 3 25 2 H Pu 2 1 238V Pu 2 2 a 23 2 N 213 3 ESS OM 5004 Fe 4 X 8 IBNAP Foa2 KAAPELI 5002 5003 SST SALZER K amp N I 1 2 de A 5 2 MSDI mit tari 17 18 SWI22 2 MU 2 2 52 5 2 5 BU N B 7 BUF 1 2 2 12 5 1 19 8 3 i PL 12 13 14 1 Y 16 T M 2 pun 18 17 2 13 T 20 21 2s La x 22 23 24 18 Y KEVI KEVI 2 5005 M 42 2 2 14 emu 26 MU 5UF Lo SI LN 980703 a KEMPPI KEMPOWELD OF SIMACO 31422980 5 54 002
22. loose Broken diode in the secondary rectifier G001 CAUSE REMEDY Check and change the fuse if needed Check the voltage from transformer in the terminal block between 2 1 and 2 2 it should be 230v Check the voltage over the pressure guard or from PCB A002 X2 1 and X2 8 enough pressure OV and lack of pressure c 5V Check and change the capacitor if needed See TROUBLE SHOOTING FOR PCBs appendix 1 Check the 24 VDC from connector X3 5 and X3 6 change valve or PCB Check change the fuse if needed Check and repair the control cable if needed See table 1 Check the motor voltage from A001 X4 12 and X4 13 max is c 24 VDC if it s all right motor is faulty See TROUBLE SHOOTING FOR PCBs appendix 1 Check all phases from the therminal block X001 Change mains fuse if needed or tighten mains cables Check that voltages are symmetric over the three spools of T001 Variation of voltage is depending on voltage selection and load normally it is between 10 VAC and 32 VAC OCV variation range is 11 VAC to 35 VAC Measure first main switch if it is all right check the contactor Check the valve according the instructions mentioned above Check repair the mig gun Check and change diode bridge if needed TECHNICAL SERVICE MANUAL FOR KEMPOWELD TROUBLESHOOTING CHART TROUBLE CAUSE REMEDY Welding stops occasionally or some Faulty intermediate cable or Check repair the cable See TABL
23. pacitor C10 MSD PoweR START gt pin X2 11 to GND OV start active 6 START gt V4 to GND OV start active TP 4 15 V FAN ON CONTROL FAN TIMER voltage over C3 under 5 V stop over 10 V on A001 WIRE FEEDER 40 V over the capacitor C3 overihsdode VIT C 7 4 Syneronizarion 19 rectified sine wave ______________ RAMP WAVE over the ss C11 the x is only active when start or wire is on 6 STARTTP13 0VON 15 7 BREAKCONTROLTP24 OVactive15Vstop 8 BURN GAS TIMER TP33 15 V stop under2Von 9 Contactor CONTROL 32 under 1 V off verb Von 10 I FAN CONTROL TP 34 under 1 V off over 10 V on ui Il FAN CONTROL voltage over the capacitor C17 lt 2 V fan off lt 6V fan on 11 SET VALUE FOR WIRE FEEDING SPEED pin X2 1 and GND voltage between 0 V 15 V depending on potentiometer setting TECHNICAL SERVICE MANUAL FOR KEMPOWELD A002 WATER COOLING UNIT 24 V over the 24 over the capacitor 85 lt lt lt C5 15 V over the 3 STARTTIP1 gt 15V 1 gt 15V PRESSURE SWITCH pin X2 1 to GND OV pressure OK 24 V no pressure THERMAL PROTECTION between pins X2 3 and X2 6 0 1 V 0 3 V normal temperature over temperature over 3V PUMP TIMER TP 3 on gt 5V off lt 1 V TP 18 0 6 V off lt 0 2 V xem ARS i 4
Download Pdf Manuals
Related Search