Kemppi WELDFORCE KPS 3500 Manuel utilisateur

Service manual

Ver. 1.0

Contents

Technical data…….……………………………....………3

Switches and connectors…....…………………………….3

Operation principle………………………………………4

Simplified main circuit diagram…….………...………...5

Main circuit components………………………………...5-8

Control cable connectors………………………………...9

Troubleshooting diagram….........……………………….10

Control card A001 layout….…………………...………..11

Control card A001 jumper….....................……………...11-12

Control card A001 leds….………….……………………12

IGBT gate pulse…...……………………………………...13

Voltage over the lower IGBT………….……………....... 14

Voltage after the secondary diode cards….………….....15

Cooling unit control…….............………………………...16

Structure (Kemppi WELDFORCETM 4500)……………...... 17

Notes……………………………………………................18

Supply voltage 3~50/60 Hz 400 V –15…+20 % 400 V –15…+20 % 400 V –15…+20 %

Loadability (+ 40°C)

60 % ED

80 % ED

100 % ED

350 A (15 kVA)

320 A (13,5 kVA)

450 A (21,5 kVA)

420 A (20 kVA)

380 A (18,5 kVA)

550 A (28 kVA)

500 A (24,5 kVA)

440 A (21 kVA)

Supply cable /

Fuses

4 x 6 S – 5 m

25 A slow

4 x 6 S – 5 m

35 A slow

4 x 6 S – 5 m

35 A slow

Adjustment range of welding current

and voltage

MMA

MIG

10 A…320 A

12 V… 37 V

10 A…420 A

12 V… 39 V

10 A…520 A

12 V… 42 V

Max. welding voltage 46 V / 300 A 46 V / 400 A 50 V / 500 A

OCV appr. 65 V appr. 65 V Appr. 65 V

Idling power < 75 W < 75 W < 75 W

Efficiency on nominal values Appr. 85 % appr. 85 % appr. 85 %

Power factor on nominal values appr. 0,93 appr. 0,93 appr. 0,93

Degree of protection IP 23 C IP 23 C IP 23 C

Weight 37 kg 41 kg 48 kg

Auxiliary units power supply 50 VDC (6,3 AT) 50 VDC (6,3 AT) 50 VDC (6,3 AT)

Technical data

KPS 3500 KPS 4500 KPS 5500

1I/0-signal lamp

2Overheat protection lamp

3 Main switch

4control cable connection fuse

6,3 A slow

5Supply cable

6,7 Welding current connections

8Return current connection

9Control cable connections

Switches and connectors

Operation principle

KEMPPI WELDFORCETM-power sources are versatile, MIG/MAG- and MMA-suitable inverters.

KEMPPI WELDFORCETM-power sources are based on IGBT technology and controlled by PWM

principle. The inverter frequency changes by the load, in range of 14 - 24 kHz.

KEMPPI WELDFORCETM-power sources are microprocessor controlled, so all welding

characteristics are programmatically generated.

KEMPPI WELDFORCETM-power source´s operation principle is shown below:

appr. + 570 V

KEMPPI WELDFORCETM-power source´s

power stage is a traditional half bridge,

where the intermediate circuit DC-voltage is

halved by working capacitors C2 and C3.

IGBT-transistors work as power switches.

When both IGBTs are non-conductive, no

power is transferred.

When the upper IGBT V2 is conductive, the

main transformer T1´s primary side has

positive voltage. When the lower IGBT is

conductive, there is negative voltage.

Power is adjusted by altering the IGBT-

transistors conductive timings (PWM).

The main transformer T1´s secondary

voltages are rectified by a full-wave

rectifier.

Voltage over the lower IGBT with minimum values.

(MIG 10A/14,5V)

100V, 20µs/DIV

UV3

Voltage over the lower IGBT with maximum values

(MIG 450A/36,5V)

100V, 20µs/DIV

Simplified main circuit diagram

Control card A001

The filter card Z004 dampens the electromagnetic disturbances conducting to the net (EMI).

Varistors (550 V) form an overvoltage protection against low energy voltage spikes. Note! Filter

card Z004 and varistors are mounted before the main switch S001!

Main circuit components

Filter card Z004 Varistors (550V)

Main switch S001

Main circuit components

Rectifier unit

3500, 4500: 60 A/ 1600 V

5500: 100 A/ 1600 V

Rectifier unit

35 A/ 600 V

Varistor

550 V

Primary choke

The primary rectifier VG101 rectifies the net voltage. The primary choke L001 limits the in-

rush current during switching and filters the DC-voltage together with the smoothing capacitors.

Smoothing capacitors

2 x 25 µF/ 700 VDC

Work capacitors

3500: 18 x 0,15 µF/ 1000 VDC

4500: 22 x 0,15 µF/ 1000 VDC

IGBT-module

3500: 100 A/ 1200 V

4500: 150 A/ 1200 V RC-protection

RC-protection

Discharge resistors

(KEMPPI WELDFORCETM 3500and 4500)

Main circuit components

Smoothing capacitors

4 x 25 µF/ 700 VDC

Work capacitors

30 x 0,15 µF/ 1000 VDC

Discharging resistors

4 x 33 kΩ/ 2 W

IGBT-modules

2 x 200 A/ 1200 V

RC-protection

Inverter´s main parts are the workcapacitors, IGBT-transistors and the main transformer T001.

Inverter´s power adjustment is based on pulse width modulation (PWM). RC-protections ease the

stress on the semiconductors.

(KEMPPI WELDFORCETM 5500)

The chokes LL301 and LL302 of the commutation unit reduce the losses of the IGBTs during

the switching. The current transformer LT301 monitors the primary side current. According

to it´s measurement the frequency of the power source is adjusted (14… 24 kHz).

Commutation unit

Main circuit components

Diode cards

Secondary choke and shunt resistor

Shunt amplifier

OCV smoothing circuit

The main transformer T001 secondary voltages are full-wave rectified by the diode cards. The

secondary voltage waves are dampened by secondary choke L002. The secondary circuit current

is measured by a shunt resistor. The shunt´s voltage is amplified by shunt amplifier A001/2 and

taken to control card A001´s PWM-adjuster.

Control cable connection power supply

+ 50 VDC

Control card A001

power supply 2 x 20 VAC

No 220 V coil!

From auxiliary transformer T002 secondary voltages are formed the supply voltages for A001

and control cable connection´s auxiliary units.

Control cable connections

The auxiliary units are connected to power source´s control cable connectors X006 and X007.

The cooling unit KWU-10 is connected to connectors X010 and X011.

KPS 4500 KPS 5500

The control card A001 is similar in all Kemppi WELDFORCETM -power sources. The machine size

is coded with short circuit loops, except in Kemppi WELDFORCETM 3500, which has no short

circuit loops.

C D

Troubleshooting

PROBLEM POSSIBLE CAUSE REMEDY

The power source will not start.

The signal lamps remain blank.

The net fuse has burnt. A faulty

supply cable.

A faulty auxiliary transformer

T002.

A faulty control card A001.

Check the net fuses. Check the 3

phases coming to power source´s

connector X1.

Check the auxiliary transformer´s

secondary voltages from control

card A001, between connectors

X12 - X11 and X12 - X10 (appr.

20 VAC).

Update the control card´s flash

memory program. If

reprogramming will not solve the

problem, replace the control card

A001.

Net fuses blow immediately

when the power source is

switched on.

A faulty primary circuit

semiconductor.

Check the semiconductors on the

primary side.

The power source doesn´t reach

maximum power.

The net fuses has blown. A faulty

supply cable. A faulty primary

rectifier VG101. A faulty secondary

diode card.

Check the net fuses, supply cable

and the primary rectifier VG101.

Check the condition of the

secondary diode cards.

The fans remain rotating after

power source startup.

A faulty control card A001. Reprogram the control card A001

flash-memory. If reprogramming

will not solve the problem, then

replace control card A001.

The machine may only be repaired by a technician or a workshop licensed and authorized to

do the job!

First do a visual check to find any possible loose connectors, broken wires or signs of

overheating.

Troubleshooting diagram

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