Service manual FastMig MXF feeders version 2.0
Contents
1. VDZ Bus mun LF asta 3 1 SA n i H A A AL 2 i n sal ah p si ciel nip demo E qui a 1 adi i D a RP b N din aA 1 Bus Data i P L un i 1 i B j T aan x4 81 Remote control Bus 50 1 po i gum p AgBI xI l ji eee connector i H 3 i r i D NE Nee EAL Eel Smet Tb E 1o d b C donde i ie T MEE 33XXxXXXXxxXxxxxix Serres i 3 j eee M We i i am 1 xwier i d n B i essei EE apa x4 1 ENP BR n 1 I A x4 A Wo mm ee ee ee eee ee ees i 1 Bus Daia H i Motor Control Card i B eee mimm 1 Bus 50 LF S d i Electromagnetic i p gas valve i Pot i i Apal 4 I E i L da E 2 i 3 i 4BBI x4 4 poU Ft ID CzH red Pot 45 4 4081 x4 6 G i ID CAM txd i e O01 i i 5 2 i GND l i r Wi me es ee ee eee et ee te eee L i LI i i L i i i LI i i L i i ee ee ee ee ee OO ee Ee ee Pee te ee ae ee ee Don Sync connector T 7 y ive i i i i D G n a 1 4 4 i es 3 KAF 280 300 i ES 4 Spool Spece Gas Guerd Poor Switch 1 _ Metor 1 5 i Heater GG 2007 300 4004 xI 7 Motor SUB 15 AgB4 1 4 B i Motor P L5 i 14H84 XI 2 Cc sure l as SSMS d iio SOY SE ee Melee aM n apa de MTS E arses A Sates Mad m Rr i it i UT f id n end es Sem ob o b o ln o Tri is d i V b hs Nate MIB V Y RT ewe 1 H Subfeedid eru e ett Da er Nn EAM a E ME EM E CERTA AUN LR e RM AL RAIL E A2. Function is not activated If function is required please order proper license Power source not connected or not identified Check the intermediate cable Feeder is powered up but it can not identify the power source Welding program not found If welding program is required please order proper welding program and license MEM ERR Error while reading or writing to memory Machine can not write to feeder memory card check the cables and connections possibly broken control memory card NO BUS Panel can not connect to the CAN bus Check the flat cables Check the panels KEMPPI The Joy of Welding rnm criurmuoP NER E OX ET ues EROS UN 1 mm mmmnmmmmm I a rea REB IRAERAP SEES T SR PU AIRE RE ESOS NI T al PR DIx connector i i i i Welding torch i cannector i i pa I B i i i i i i wba i I H L H 1 apice AA SOTS S aN eT E A S O ee Ee EE d i s i Start 2 2 2 3 i i to Printed circuit boards p OR X402 ee a 1 rH z H L gt 1 m L 4 i OBI pene we UV uyuE jek gi i ammi x4 s Bi ert Wid i od r4 Loan ra go n ta ab aw D i i Pod 8 E H E N gggsgusug 89s B i i i 1 wool Zz ZZZ xz xx O zQ a i agi i i a ai x 3 x xxu x fF We me me me me em me ee ee eee ee eee 1 4 DAR E EEEE AEI N E EEN i i j Bus i E i i gt connector E amp raf z A i i i i iy amp n A Memor vcard SEON E E E E EA
3. Motor voltage Motor voltage can be measured by oscilloscope and DMM Creep start have to be switched off to measure needed voltages e To change this function Use power source setup panel and select Edit channel Tek e Welding functions e Values 10 99 off curve select off Motor voltage by oscilloscope e Measuring points X4 3 motor voltage positive X4 15 motor voltage negative Ch4 Freq e See attached oscilloscope picture 16 46kH2 Pulse width depends on set value Voltage peak value 50VDC CAN bus voltage cha D Motor voltage by DMM e Measuring points X4 3 motor voltage positive m X4 15 motor voltage negative EATE ITYU Wire feed speed is comparable to motor voltage Gm 200V 26 May 2009 Approx 1V 1m min is 20 20 09 56 24 KEMPPI The Joy of Welding Tacho signal Tacho signal can be measured by oscilloscope and DMM Tacho signal by oscilloscope e Measuring points X1 5 ground X1 6 tacho signal e Signal may vary e Voltage range 0 5V Duty cycle 50 AE NE a MOM NMX Frequency range 25 600Hz T TEE Em lex aid sep Medus Tek Stop Tacho signal by DMM Measuring points Ch4 Freq 123 9 H2 X1 5 ground ues sees reas gestae l J Hsc T deis X1 6 tacho signal l Ho Ror2ms e Wire feed motor static tacho signal 5VDC l w 5 5 esaa snes W 9 Je cm Wd s ai o c 3 5 bor s s se 5 ee 5m min 2 7VDC p S i 1Om min 2
4. 65VDC A uM T x M gi gt 15m min 2 6VDC ia aa LL a aaa e 20m min 2 5VDC 000 M 00ms Al chg f 2 84V in 2 00 V 25m min 2 45VDC L MIKEA So ay a003 Note Wire feed motor running at a very fast speed could mean a problem with the tacho feedback signal KEMPPI The Joy of Welding Gas valve control Gas valve control can be measured by oscilloscope and DMM Gas valve control by oscilloscope Measuring points X4 10 gas valve ground X4 12 gas valve positive Gas valve control is two stage Duty cycle e First 100ms 500Hz 50 e Then 250Hz 25 Voltage peak value 50VDC CAN bus voltage Gas valve control by DMM Measuring points X4 10 gas valve ground X4 12 gas valve positive e Can be measured only a second stage e Voltage cam be calculated from following equation U ss 0 25x50VDC 12 5VDC KEMPPI The Joy of Welding Tek Prevyu M 20 0ms Al Ch4 14 8 V 20 0 V 3 2 800 Ch4 Freq 494 9 HZ Ch4 Period 2 020ms 25 May 2009 13 29 33 Motor control card
5. Are there any breaks in the cables Are the cables correctly connected Are there any loose components Are mains fuses circuit breakers OK amp correct valves e Any signs of burning or arching Connect the machine to the mains input supply and check Is there a stable 50VDC input inside the machine Is the machine in shut down mode s there any error codes Are the user settings OK KEMPPI The Joy of Welding Motor Control Card A001 layout X11 X3 COILTRONICS VF4 0140 24CH0TH PAPEN m 14 te 2H E mn rt Fi w y El ees SER of 3 eris 40 war CER va HEE E27 R32 E 4 i J TAG CONNECTOR te eee TTTTEM Bie SEIEN o eve mrs E Ka X13 X6 BUS LED X5 A003 MEMORY CARD The Joy of Welding KEMPPI Motor control card A001 voltages A001 motor control card power supply generates several voltages from 50VDC These voltages can be measured in several points Ground is located in X1 4 50VDC CAN bus voltage in X1 1 in upper right corner e 9 6VDC in X3 8 third row from bottom second column from left e 5VDC in test point 3 3VDC in regulator N2 pin 3 third from bottom Note Be careful when measuring voltage to avoid unnecessary short circuit X3 8 9 6VDC N1 PIN 3 3 3VDC Sa o o0 e SS iz o TEST POINT 5VDC aas ci X1 1 50VDC KEMPPI The Joy of Welding
6. starts all LEDs light and all the display segments should be on during this period of any of the buttons are pressed all led light turn off and panel software version number is shown in display This function can be used to test the panel buttons and LEDs displays This test mode is only possible when panel is starting KEMPPI The Joy of Welding Sync card A004 layout and connectors s o o ow A Umem s o o ws a E a EE NN om a 8 EL emmeteseim a a E E EE ws A I N a w m I I gt suue a eer theo d 9 CX LIC 211 ew vty E amt zd49 2d reU S Der 92tenr 1 1 ye KEMPPI The Joy of Welding Sync card A004 voltages SuperSnake sync card has two input voltages and control signal to motor speed Lack of these voltages may be the problem in connections between the A001 and A004 or in the feeder A001 control card itself e GND is located in A004 sync card connector X1 6 RB ARII X VI7 7 NS VB APRESS LRL LR ME LL So 4A BERE E EE Voltage to feeding motor power supply 50VDC in A004 sync card connector X1 1 rd If voltage is missing sub feeder motor won t be running pow AV he m Voltage to feeding motor control electronics 9VDC in A004 sync card connector X1 8 X1 If voltage is missing sub feeder motor won t be running Motor speed control signal e Voltage range is between 0 4 5VDC in connector X1 12 e OVDC motor stopped e Any voltage motor should be ru
7. A001 connectors Gommectorpin Connector type Commestorpim _ Connector ype ow qm o m ow eno m X1 1 board X4 1 board Low a oe xw omesses ow os ENCNN S NNE 777 NN ow E oe ow oes ee o 3 X3 1 board s sana e 1 mess Cae O ees xw fst wn GN X3 6 D SubMotor X3 4 X3 7 X3 8 9V ms X3 9 SubMotor xo Meas EMF Sup X3 12 3 Sub Control KEMPPI The Joy of Welding Motor control card A001 connectors X5 1 2 pin wire to board Gas guard X5 2 MATE N LOCK2 Gas guard X6 1 2 pin wire to board Door switch X6 2 MATE N LOCK2 Door switch 20 pin box header JTAG production programming 6 pin header Memory board connector Plated PCB hole Chassis ground Tab terminal 6 3mm Chassis ground Tab terminal 6 3mm Spool space heater Tab terminal 6 3mm Spool space heater Tab terminal 6 3mm GND panel board KEMPPI The Joy of Welding Welding panel card P001 layout FUNCTION BUTTONS Regii 24m TH gt p 9 57 4 amp BUS CONNECTOR X1 SEVEN SEGMENT DISPLAYS JUMPER CONNECTOR FOR FUTURE PURPOSE PULSE POTENTIOMETERS J TAG CONNECTOR FUNCTION BUTTONS SEVEN SEGMENT DISPLAY MICROPROCESSOR S KEMPPI The Joy of Welding Welding panel card P001 connectors and testing PF65 X1 and P65 X1 CAN bus interfaces are identical Both Panels use CAN interface and KeBus protocol BH CHEM 09 When panel
8. NE RRS nt EDAD ee MR ABAI 3 7 Dn e i i Wi te i Ei i Wire feed motor P Fi Y rt i s i i 400l 4 15 Motor al MP_Tacho input i wpo2 a i EN odio EN LLLLLLLLLLL OOo vel GND oo MI 2 i i i Notes i i A i i x 1 AgBI XI 5 Tacha Signal 3 Dut i i i option i Tacha GND ABOS i P i 4001 1 5 GND gt mao o QU i Tacha 5 Tachometer i 1 AADI x1 3 t8v Card 7 i H i n Eod LC c TAPPA Peria i EE FASTMIG PULSE Perte lo i 3 21 i AADI x4 3 i MXF 65 ALM OHIE i i Wr 4 mes By kES 54 og2 WOBO 385584 i p Main Circuit Diagram
9. and panel compatibility Feeder and SuperSnake compatibility Power source and feeder compatibility KEMPPI The Joy of Welding Error codes Err 1 Power source not calibrated or calibration data cannot be Restart power source if the problem continues after multiple startups check the power read source control cards Over voltage mains supply Check the main voltage Err 4 Over heat power source Do not shut down the machine cooling fans will cool the machine Check the ventilation If cooling fans are not running check the power source connections and voltages Err 5 Auxiliary voltage 15VDC too low control card led H9 Main supply voltage is too low or aux supply faulty check the main aux supplies Can 15VDC show up also if one of the mains phases is missing Note Only one of the three phases can affect this error if missing one where aux transformer is NOT connected Err 8 FPGA not configured Restart the power source if the problem continues after multiple startups check the power source control cards Err 27 Water cooler error Check the water cooler connections and functions For more details check the cooler service manual WF Motor over current warning delayed fault at 3 5A Check the gun and the consumable parts WF Motor over current error delayed lock at 5A Check the gun and the consumable parts Gas guard alert only if gas guard connected and activated Check the shielding gas gas guard and all the connections
10. at first and then stops working afterwards The reason may well be that some of its components are damaged by ESD Memory circuits are especially sensitive It may be that a memory circuit damaged by ESD breaks down only weeks later It looks like a software problem but in fact it is a tiny defect in the memory circuit itself A simple effective enough way to protect against ESD is to wear an earth bracelet when handling electronic circuits or cards The bracelet is earthed to the frame of the appliance being serviced An equally important shielding device is an earth pad on the workbench Also wearing clothing manufactured from natural fiber cotton decreases electrical charging All Kemppi factory parts susceptible to ESD e g control cards are delivered in packaging or pouches that protect and earth the components Packets and pouches carry yellow ESD labels Parts susceptible to ESD must be kept in their original packages only removed just before installation Article taken and abridged from Kemppi PRONEWS Parts subject to ESD are labelled as such KEMPPI The Joy of Welding Tools and testing equipments While repairing Kemppi machines there is no need to have any special hand tools Most of the work can be done with normal workshop tools and testing can be done by digital multimeter and Kemppi Multipower or a standard workshop power source v Hand tools and accessories Metric combination wrenches 8 19mm 28mm Screwdrive
11. eK The Joy of Welding Service manual FastMig MXF feeders version 2 0 Released 20 01 2010 WARNING Before removing any covers or commencing any testing or measurement disconnect the power source from the mains voltage Wait at least one minute for the capacitors to become discharged The device may be repaired only by a person legally authorized to perform electric work KEMPPI The Joy of Welding Electrostatic Discharge Electrostatic discharge ESD is phenomenon that occurs almost everywhere and often At its most powerful it is known as thunder and lightning electrical charges as high as one billion volts can be discharged between clouds or between clouds and the ground below This type of electrical discharge cannot occur at normal ground level of course Movement and friction generate static discharges of a few thousand volts in certain conditions For example stroking a cat can generate thousands of volts Electronic appliances welding machines included are now designed and manufactured in ways that take into account the ESD problem It is only apparent when an appliance is taken apart for servicing At that time the ground terminal is often disconnected and sensitive electronic components can be prone to electrostatic discharge The best way to protect against ESD when handling electronic cards or microchips is an earth connection You frequently hear of people who wonder why a new unused electronic card works
12. nning higher value faster speed If connection is lost motor will be running at very fast speed and probably won t stop Note If X1 9 is disconnected voltage feedback is lost and wire feed motor runs at very fast speed but it stops when start is disconnected KEMPPI The Joy of Welding Construction left side A003 MEMORY CARD A001 CONTROL CARD A004 SYNC CARD GAS VALVE DURA TORQUE ID CHIP KEMPPI The Joy of Welding Construction right side DT400 WIRE REEL KEMPPI The Joy of Welding Panel communication ParameterTable WeldingProcess MemoryChannelNumber WF Speed Finetuning KeBUS KeFS KeBUS KeFS KeBus Kemppi BUS Parameter Table Parameter Memory System BUS that controls Parameter and File transfer KeFS Kemppi File System System function that controls file transfer KEMPPI The Joy of Welding Panels use ParameterTable to direct panel to panel communication System Database System Memory 10 users 10 Memory channels 10 users 10 Recall memory channels used in restore user settings Setup parameters Other system setting Error log Curves Fastmig Pulse compatibility Fastmig pulse family and SuperSnake can be used with synergic family with some limitations SuperSnake won t work with KMS MSF SF MSF feeders won t work with FM Pulse power source New MXF welding panel PF65 won t work on MSF Feeder
13. rs flat 0 5 x 3mm and torx T10 T25 Needle nose pliers Side cutters Cable ties Testing equipments Digital multimeter True RMS 800VDC 600VAC for safe operation Regular workshop power source with 50VDC output or Kemppi Multipower 50VDC Useful extra tools Digital oscilloscope 10MHz or greater i ur KEMPPI The Joy of Welding General service procedure It is recommended that a systematic method is used on all repair or maintenance work each repair is a special case and should be handled as required but by following a routine less mistakes and safety issues will occur Here is an example of a general routine 1 General troubleshooting 2 Static tests 3 Repair work 4 Test welding Always try to isolate failure to certain blocks This manual has several tests to make conclusions and to isolate the problem Be careful not to make assumptions because it might lead you to change the wrong parts KEMPPI The Joy of Welding General troubleshooting Always try to get a detailed description of the complaint This troubleshooting guide is to remind the service technician to check the simple things first a visual inspection can often help with fault finding If visual damage can be seen replace all broken parts If everything looks normal or broken parts are changed it is recommended that a low voltage test is carried out Disconnect the machine from the input supply and remove covers then check
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