Kemppi
Kemppi
Kemppi
MANUAL FOR
KEMPOWELD MACHINES
TECHNICAL SERVICE MANUAL FOR KEMPOWELD
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
The KEMPOWELD won´t start at all, Blown fuse in mains supply voltage. Check all three supply voltage
any of the auxiliary devices won´t phases; check fuses.
start.The signal lamps of machine
are not switched on. Faulty mains cable. Check mains voltage from terminal
block X001, repair cable if needed.
The wire feeding unit K200/400 Faulty connection in control lines. See, TABLE FOR CONTROL
won´t work. LINES, table 1.
The cooling unit don´t start or pilot Blown fuse F002 2A. Check and change the fuse if
lamp Hw3 lacking water pressure is needed.
iluminated.
Auxiliary transformer T002. Check the voltage from transformer
in the terminal block between 2.1
and 2.2, it should be 230v.
The solenoid valve Y001 don´t work. Faulty solenoid valve or PCB A001. Check the 24 VDC from connector
X3/5 and X3/6, change valve or
PCB.
Wire feeding motor don´t work. Blown fuse F001 8A Check/change the fuse if needed.
The control cable between feeder Check and repair the control cable if
and power souce is broken or it is needed. See table 1.
not properly tightened.
Faulty motor or PCB A001in Check the motor voltage from A001
K200/400. X4/12 and X4/13 max. is c. 24 VDC,
if it´s all right motor is faulty.
Welding quality is bad: One phase is missing. Check all phases from the therminal
block X001. Change mains fuse if
- arc is not stable needed or tighten mains cables.
- there are lot of spatters
- bad arc start Faulty main transformer T001. Check that voltages are symmetric
- not enough arc voltage 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
Faulty main switch S001 or contactor Measure first main switch if it is all
K001. right check the contactor.
Welding stops occasionally or some Faulty intermediate cable or Check/repair the cable. See TABLE
other occasional disturbances. connector. FOR CONTROL LINES, table 1.
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.
Wire feeding speed set value can´t The set value potentiometer RW102 Check and change the 10KΩ
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.
Occasional disturbances with KMW- Ribbon cable between KMW-timer Check and tighten the ribbon cable.
timer unit. and control card A001 is loose or
cut.
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.
A
B
C
D
E
F M
HC-start
G
H
TECHNICAL SERVICE MANUAL FOR KEMPOWELD
PICTURE 2. A004 MP-SYNC CONTROL CARD
X1
X2
X3
A004
R 15
R 19
R 11
X1
V2 V3
X6
X3
C3
C4 C5 C6
X7
R24
X4