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
TROUBLECAUSEREMEDY
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 K200/400
won´t work.
Blown fuse in mains supply voltage.
Faulty mains cable.
Broken main switch.
Faulty auxiliary transformer T002 or
bad connection in connector X9,
400V or 0V.
Blown fuse F001 8A.
Faulty connection in control lines.
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 CONTROLLINES, table 1.
Blown fuse F001 8A.
Broken PCB.
Check/change fuse F001.
See, TROUBLE SHOOTING FOR
PCBs appendix 1.
TECHNICAL SERVICE MANUAL FOR KEMPOWELD
TROUBLESHOOTING CHART
TROUBLECAUSEREMEDY
The cooling unit don´t start or pilot
lamp Hw3 lacking water pressure is
iluminated.
The solenoid valve Y001 don´t work.Faulty solenoid valve or PCB A001.Check the 24 VDC from connector
Wire feeding motor don´t work.Blown fuse F001 8A
Blown fuse F002 2A.
Auxiliary transformer T002.
Pressure switch S005
5µF capacitor C001.
Broken PCB.
The control cable between feeder
and power souce is broken or it is
not properly tightened.
Faulty motor or PCB A001in
K200/400.
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 0V and lack
of pressure c. 5V.
Check and change the capacitor if
needed.
See, TROUBLE SHOOTING FORPCBs appendix 1.
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.
Welding quality is bad:
- arc is not stable
- there are lot of spatters
- bad arc start
- not enough arc voltage
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 loose.
Broken diode in the secondary.
rectifier G001.
See, TROUBLE SHOOTING FORPCBs 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
TROUBLECAUSEREMEDY
Welding stops occasionally or some
other occasional disturbances.
Machine is overheating because the
fan don´t start.
Wire feeding speed set value can´t
adjusted.
KMW-sync is not working.Faulty connection in connector X1.Check and repair connection
If some other push-pull gun than
Binzel or Hulftegger is in use the gun
is pulling to fast.
Faulty intermediate cable or
connector.
Faulty switch in mig gun.
Loose start wire(s) in mig gun.
Faulty fan or PCB A001 .Check the 24 VDC voltage from fan
The set value potentiometer RW102
is faulty.
Wrong motor voltage.Select correct jumper combination
Check/repair the cable. See TABLEFOR CONTROL LINES, table 1.
Check and change the switch if
needed.
Check and tighten the start wire(s)
inside the gun.
connector X2/12 and X2/13, if it is all
right change the fan, if it is not
change the PCB.
See, TROOUBLE SHOOTING FORPCBs appendix 1.
Check and change the 10KΩ
set value potentiometer RW102 if
needed.
according to PICTURE 1.
(there are two jumpers X1 and X2
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
Occasional disturbances with KMWtimer unit.
The water circulation stops after 5 s
of welding.
control card A001 is loose or cut.
Faulty MSD-1 unit.
Ribbon cable between KMW-timer
and control card A001 is loose or
cut.
Faulty KMW-timer unit.
Low cooling water volume.
Air bubbles or leakages in cooling
system.
Faulty pressure switch
Check and tighten the cable, check
also the control voltage for MSD-1
from A001 X3/16 and X3/1 the value
should be 12 V.
Check as mentioned above if it´s all
right, chage the MSD-1.
Check and tighten the ribbon cable.
Check and change the KMW-timer
unit. See also potentiometers from
PICTURE 3.
Check the water and fill it if needed.
Follow the instructions of
Kempoweld Operation Instructions/
Operation Disturbances.
Check/change the pressure switch.
TECHNICAL SERVICE MANUAL FOR KEMPOWELD
TABLE 1. CONNECTORS AND CONTROL LINES
KEMPOWELD CONNECTORS X006 AND K200/400 XW101
XW101 / X006K200/400
A001
B
C
D
PICTURE 1. KMW-SYNC CONNECTION
X3/1X8/330 VAC
X3/8X2/130 VAC
X3/7X2/11START
A
B
C
D
KEPOWELD
A001
VALUE
E
F
G
H
HC-start
M
TECHNICAL SERVICE MANUAL FOR KEMPOWELD
A
X2X
X
X
PICTURE 2. A004 MP-SYNC CONTROL CARD
1
3
004
PICTURE 3. PCB OF K400 TIMER UNIT
R 19
R 15
R 11
1
Potentiometers:R11 = Gas post flow
R15 = Cycle time
R 19 = Pause time
TECHNICAL SERVICE MANUAL FOR KEMPOWELD
V2V
X
PICTURE 4. A001 PCB OF K400
3
X6
X3
C4
C5
C6
4
Potentiometer:R24 = Adjustment of wire feed speed
C3
X7
R24
TECHNICAL SERVICE MANUAL FOR KEMPOWELD
APPENDIX 1. TROUBLESHOOTING FOR PCBs
A001 POWER SOURCE
1.+ 24 V over the capacitor C9
2.
3.+ 15 V over the over the diode V2
4.
5.
6.
7.
8.
A001 WIRE FEEDER
1.30 VAC between the thyristros anodes
2.+ 40 V over the capacitor C3
3.+ 15 V over the diode V17
4.
5.
6.
7.
8.
9.
10.
11.
+ 24 V over the capacitor C7 (FAN POWER SUPPLY)
+ 12 V over the capacitor C10 (MSD
POWER SUPPLY)
START => pin X2/11 to GND, 0V = start active
START => V4 to GND, 0V = start active
TP 4 = 15 V, FAN ON CONTROL
FAN TIMER voltage over C3 under 5 V = stop, over 10 V = on
SYNCRONIZATION TP 19 (rectified sine wave)
RAMP WAVE over the capacitor C11 (the wave is only active when start
or wire feeding is on)
START TP13; 0V ON, 15 V STOP
BREAK CONTROL TP24 ; OV active 15 V stop
BURN BACK/POST GAS TIMER TP33; 15 V stop, under 2V on
CONTACTOR CONTROL TP 32; under 1 V off, over 5 V on
I FAN CONTROL TP 34; under 1 V off, over 10 V on
II F
AN CONTROL, voltage over the capacitor C17 < 2 V fan off
< 6V fan on
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
1.+ 24 V over the capacitor C5
2.+ 15 V over the capacitor C6
3.
4.
5.
6.
START TP 1 => 15 V
PRESSURE SWITCH pin X2/1 to GND; 0V 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 > 5 V