Kemppi Kempact 253R, Kempact 251R, Kempact 251A, Kempact 181A, Kempact 253A Service Manual

SERVICE MANUAL

KEMPACT RA

Kemppi Oy

181A
251R/251A
253R/253A
323R/323A
253MV/323MV

SERVICE MANUAL

CONTENTS

1. PARTS OF MACHINE................................................................................................................................................................................ 3

2. TECHNICAL INFORMATION ..................................................................................................................................................................... 5

2.1. Technical data ................................................................................................................................................................................ 5

2.2. Main circuit diagrams ..................................................................................................................................................................... 9

3.1. Main components ........................................................................................................................................................................ 13

3.1.1. Terminal block X001 ............................................................................................................................................................. 13

3.1.2. Varistors R001 ...................................................................................................................................................................... 13

3.1.3. Main switch S001 ................................................................................................................................................................. 13

3.1.4. Terminal block X009 ............................................................................................................................................................. 13

3.1.6. Test connector X006 ............................................................................................................................................................ 13

3.1.7. Auxliary transformer T002 and rectifier bridge G003 .......................................................................................................... 13

3.1.8. Control card A001 ................................................................................................................................................................ 13

3.1.8.1. Auxiliary power supply ................................................................................................................................................ 13

3.1.8.2. Microcontroller ............................................................................................................................................................ 13

3.1.8.3. Motor control .............................................................................................................................................................. 13

3.1.8.4. PWM ............................................................................................................................................................................ 14

3.1.9. Fans M001, M002 ................................................................................................................................................................ 14

3.1.10. Solenoid valve Y001 ........................................................................................................................................................... 14

3.1.11. Wire feed motor M003 ...................................................................................................................................................... 14

3.1.12. Brights led card P002 ......................................................................................................................................................... 14

3.1.13. Panel card P001 ................................................................................................................................................................. 14

3.1.14. Main transformer T001 ...................................................................................................................................................... 14

3.1.15. Secondary rectifier card Z002 ............................................................................................................................................ 14

3.1.16. Secondary choke L001 ....................................................................................................................................................... 15

3.1.17. Output RFI filter C001, C002 .............................................................................................................................................. 15

3.1.18. Output terminal X004 ........................................................................................................................................................ 15

3.1.19. Euro connector X005.......................................................................................................................................................... 15

3.2. Main circuit diagram 181-, 251-models ....................................................................................................................................... 15

3.2.1. PFC Choke L002 .................................................................................................................................................................... 15

3.2.2. PFC circuit auxiliary transformer T003 ................................................................................................................................. 15

3.2.3. Main circuit card Z001 ......................................................................................................................................................... 15

3.2.3.1. EMC Filter .................................................................................................................................................................... 15

3.2.3.2. Inrush current limiting ................................................................................................................................................. 15

3.2.3.3. IGBT driver ................................................................................................................................................................... 15

3.2.3.4. Current transformer T1 ............................................................................................................................................... 15

3.2.3.5. Main circuit .................................................................................................................................................................. 15

3.2.3.6. PFC Boost control circuitry .......................................................................................................................................... 16

3.3. Main circuit diagram 253-, 323-models ....................................................................................................................................... 16

3.3.1. Main circuit card Z001 ......................................................................................................................................................... 16

3.3.1.1. EMC filter ..................................................................................................................................................................... 16

3.3.1.2. Inrush current limiting ................................................................................................................................................. 16

3.3.1.3. IGBT driver ................................................................................................................................................................... 16

3.3.1.4. Current transformer T1 ............................................................................................................................................... 16

3.3.1.5. Main circuit .................................................................................................................................................................. 16

3.4. Main circuit diagram 253MV-, 323MV-models ............................................................................................................................ 18

3.4.1. General ................................................................................................................................................................................ 18

3.4.2. Main circuit card Z001 ......................................................................................................................................................... 18

3.4.2.1. EMC filter ..................................................................................................................................................................... 18

3.4.2.2. Inrush current limiting ................................................................................................................................................. 18

3.4.2.3. IGBT driver ................................................................................................................................................................... 18

3.4.2.4. Current transformer T1 ............................................................................................................................................... 18

3.4.2.5. Main circuit .................................................................................................................................................................. 18

3.4.2.6. PFC Boost control circuitry .......................................................................................................................................... 18

4. MAIN CIRCUIT CARD Z001 .................................................................................................................................................................... 19

KEMPACT RA_V_1.2

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4.1. Kempact 181, 251 ........................................................................................................................................................................ 19

4.1.1. Connectors ........................................................................................................................................................................... 19

4.2. Kempact 253, 323 ........................................................................................................................................................................ 21

4.2.1. Connectors ........................................................................................................................................................................... 21

4.3. Kempact 253MV, 323MV ............................................................................................................................................................. 23

4.3.1. Connectors ........................................................................................................................................................................... 23

5. SECONDARY RECTIFIER CARD Z002 ...................................................................................................................................................... 25

5.1. Connectors ................................................................................................................................................................................... 25

6. CONTROL CARD A001 ........................................................................................................................................................................... 26

6.1. Leds .............................................................................................................................................................................................. 26

6.2. Connectors ................................................................................................................................................................................... 26

7. PANEL CARD P001 ................................................................................................................................................................................ 28

7.1. Connectors ................................................................................................................................................................................... 28

8. OPERATIONAL MEASURINGS AND TESTS ............................................................................................................................................. 29

8.1. Kempact 181, 251 ........................................................................................................................................................................ 29

8.1.1 Primary rectifier V24, 25 ....................................................................................................................................................... 29

8.1.2. IGBT module V1 ................................................................................................................................................................... 30

8.2. Kempact 253, 323 ........................................................................................................................................................................ 31

8.2.1. Primary rectifier, V1 ............................................................................................................................................................. 31

8.2.2. IGBT module, V2 ................................................................................................................................................................. 32

8.3. Kempact 253MV, 323MV ............................................................................................................................................................. 33

............................................................................................................................................................................................................ 33

8.3.1. Primary rectifier, V31 ........................................................................................................................................................... 33

8.3.2. IGBT module, V1 ................................................................................................................................................................. 34

8.5. PTC’s, overheat protection ........................................................................................................................................................... 36

8.6. Control card A001 ........................................................................................................................................................................ 36

9. MAIN COMPONENTS INSTALLATION .................................................................................................................................................... 36

9.1. Main circuit card Z001 .................................................................................................................................................................. 36

9.2. Secondary rectifier card Z002 ...................................................................................................................................................... 37

9.3. Other components ....................................................................................................................................................................... 37

10. ERROR CODES ..................................................................................................................................................................................... 38

General

Kempact RA(Regular / Adaptive ) welding machines are compact MIG/MAG welding machines designed for professional use.

The power source part of the machine is based on inverter technology. IGBTs are used as power switches in the inverter. Kem­pact RA welding machines also contain all circuitry that is needed to drive wire feeder part of the machine and also easy to use
intuitive user interface. Most of the welding machine functions are controlled using a microcontroller.

Before removing any covers or commencing any testing or measurement disconnect the power source from the mains voltage.
Dangerous DC voltage may still exist after the removal of the input voltage. Machine discharges the voltage while it is turned
off, but it is always better to ensure this by measuring the voltage.

Digital multimeters may give different values depending the specifications they have. For example diode measuring values may
vary between the multimeters models. Special attention must be considered while working with the internal parts.

The device may be repaired only by a person legally authorized to perform electrical work.

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KEMPACT RA_V_1.2

2 (40)

SERVICE MANUAL

KEMPACT RA_V_1.2

1. PARTS OF MACHINE

3 (40)

Kempact RA (253, 323)

Kemppi Oy

SERVICE MANUAL

KEMPACT RA_V_1.2

4 (40)

Kempact RA (253, 323)

NOTE !
Spare part info available from:

Kemppi Oy

[e-mail]

(email).

SERVICE MANUAL

100% EDI1eff (14

0A) 16A

100% EDI1eff (150A)

17A

No load voltage

36V 36V

Filler wires

Fe solid

0.8…1.2 mm

0.8…1.2 mm

Standards

IEC 60974

-1

IEC 60974

-1

KEMPACT RA_V_1.2

5 (40)

2. TECHNICAL INFORMATION

2.1. Technical data

Kempact 181A Kempact 251R, 251A

Connection voltage 50/60Hz 230V+- 15% 1~ 50/60Hz 240V+- 15% 1~

Rated power at max. current 50% ED I1max (180A) 5.16VkA/5.1kW 30% ED I1max (250A) 8.5kVA/8.4kW

Supply current 50% ED I1max (180A) 22A 30% ED I1max (250A) 36A

3G1.5 (1.5mm2,

Connection cable H07RN-F

Fuse Type C 16A Type C 20A

Welding range

Idle power 35W 35W

Power factor at max. 180A/25,75V 0.99 250A/26.5V 0.99

Efficiency at 100% ED 140A/21V 0.82 150A/21.5V 0.82
Wire feed speed adjustment
range 1.0-14.0m/min 1.0-18.0m/min

Voltage adjustment range 8.0-26.0V 8.0-29.0V

Fe cored wires 0.8…1.2 mm 0.8…1.2 mm

Ss 0.8…1.2 mm 0.8…1.2 mm

Al 1.0…1.2 mm 1.0…1.2 mm

CuSi 0.8…1.0 mm 0.8…1.0 mm

wire spool max 300 mm/ 20 kg 300 mm/ 20 kg

Shielding gases

External dimensions LxWxH 623x579x1070 mm LxWxH 623x579x1070 mm

Not including gun and

Weight

Temperature class F(155 C) F(155 C)

EMC class A A

Degree of protection IP23S IP23S

Operating temperature range -20…+40 °C -20…+40 °C

Storage temperature range -40…+60 °C -40…+60 °C

gables 44 kg

5m) H07RN-F

10V/20A ­26V/180A

CO2, Ar, Ar+CO2
mixed

Not including gun and
gables 44 kg

3G2.5 (2.5mm2,
5m)

10V/20A ­29V/250A

CO2, Ar, Ar+CO2
mixed

IEC 60974-5 IEC 60974-5

IEC 60974-10 IEC 60974-10

IEC 61000-3-12 IEC 61000-3-12

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SERVICE MANUAL

Kempact 253R, 253A

Kempact 323R, 323A

Fuse Type C

10A Type C

10A

EMC class

A A

Connection voltage 50/60Hz 400V+- 15% 3~ 50/60Hz 400V +- 15% 3~

Rated power at max. current 40% ED I1max (250A) 8.34kVA/7.73kW 35% ED I1max (320A) 12kVA/11.3kW

Supply current 40% ED I1max (250A) 11.9A 35% ED I1max (320A) 17.2A

100% EDI1eff (150A) 6.1A 100% EDI1eff (190A) 8.2A

4G1.5 (1.5mm2,

Connection cable H07RN-F

5m) H07RN-F

KEMPACT RA_V_1.2

4G1.5 (1.5mm2,
5m)

6 (40)

10V/20A -

Welding range

No load voltage 41V 45V

Idle power 25W 25W

Power factor at max. 250A/26.5V 0.93 320A/30V 0.94

Efficiency at 100% ED 150A/21.5V 0.88 190A/23.5V 0.86
Wire feed speed adjustment
range 1.0-18.0m/min 1.0-20.0m/min

Voltage adjustment range 8.0-31.0V 8.0-32.5V

Filler wires Fe solid 0.8…1.2 mm 0.8…1.2 mm

Fe cored wires 0.8…1.2 mm 0.8…1.2 mm

Ss 0.8…1.2 mm 0.8…1.2 mm

Al 1.0…1.2 mm 1.0…1.2 mm

CuSi 0.8…1.0 mm 0.8…1.0 mm

wire spool max 300 mm/ 20 kg 300 mm/ 20 kg

Shielding gases

External dimensions LxWxH 623x579x1070 mm LxWxH 623x579x1070 mm

Not including gun and

Weight

Temperature class F(155 C) F(155 C)

gables 44 kg

31V/250A

CO2, Ar, Ar+CO2
mixed

Not including gun and
gables 44 kg

10V/20A -

32.5V/320A

CO2, Ar, Ar+CO2
mixed

Degree of protection IP23S IP23S

Operating temperature range -20…+40 °C -20…+40 °C

Storage temperature range -40…+60 °C -40…+60 °C

Standards IEC 60974-1 IEC 60974-1

IEC 60974-5 IEC 60974-5

IEC 60974-10 IEC 60974-10

IEC 61000-3-12 IEC 61000-3-12

Kemppi Oy

SERVICE MANUAL

Kempact 253 MV

Kempact 323 MV

40% ED I1max

35% ED I1max

Supply current

(250A)(230V)

22.2A

(320A)(230V)

33.3A

100% EDI1eff

100% EDI1eff

10V/20A

-

10V/20A

-

wire spool

max 300 mm/ 20 kg

300 mm/ 20 kg

Temperature class

F(155 C)

F(155 C)

KEMPACT RA_V_1.2

7 (40)

Connection voltage 50/60Hz

40% ED I1max

Rated power at max. current

(250A)(230V) 8.84kVA/8.38kW

(250A)(400V) 8.54kVA/8.0kW
40% ED I1max

40% ED I1max
(250A)(400V) 12.3A
100% EDI1eff
(150A)(230V) 10.8A

(150A)(400V) 6.2A

230V -15% ... 400V
+15% 50/60Hz

35% ED I1max
(320A)(230V) 13.21kVA/12.47kW

(320A)(400V) 12.37kVA/11.73kW
35% ED I1max

35% ED I1max
(320A)(400V) 17.8A
100% EDI1eff
(190A)(230V) 14.8A

(190A)(400V) 8.3A

230V -15% ... 400V
+15%

4G1.5 (1.5mm2,

Connection cable H07RN-F

5m) H07RN-F 4G1.5 (1.5mm2, 5m)

Fuse Type C (230V) 16A Type C (230V) 16A

Type C (400V) 10A Type C (400V) 10A

Welding range

31V/250A

32.5V/320A

No load voltage 46V 50V

Idle power 35W 35W

Power factor at max. 250A/26.5V (230V) 0.94 320A/30V (230V) 0.94

250A/26.5V (400V) 0.93 320A/30V (400V) 0.94

Efficiency at 100% ED 150A/21.5V (230V) 0.79 190A/23.5V (230V) 0.80

150A/21.5V (400V) 0.82 190A/23.5V (400V) 0.83
Wire feed speed adjustment
range 1.0-18.0m/min 1.0-20.0m/min

Voltage adjustment range 8.0-31.0V 8.0-32.5V

Filler wires Fe solid 0.8…1.2 mm 0.8…1.2 mm

Fe cored wires 0.8…1.2 mm 0.8…1.2 mm

Ss 0.8…1.2 mm 0.8…1.2 mm

Al 1.0…1.2 mm 1.0…1.2 mm

CuSi 0.8…1.0 mm 0.8…1.0 mm

Shielding gases

External dimensions LxWxH 623x579x1070 mm LxWxH 623x579x1070 mm

Not including gun and

Weight

gables 44 kg

EMC class A A

Degree of protection IP23S IP23S

Operating temperature -20…+40 °C -20…+40 °C

Kemppi Oy

CO2, Ar, Ar+CO2
mixed

CO2, Ar, Ar+CO2
mixed

Not including gun and
gables 44 kg

SERVICE MANUAL

range

Storage temperature range -40…+60 °C -40…+60 °C

Standards IEC 60974-1 IEC 60974-1

IEC 60974-5 IEC 60974-5

IEC 60974-10 IEC 60974-10

IEC 61000-3-12 IEC 61000-3-12

KEMPACT RA_V_1.2

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SERVICE MANUAL

KEMPACT RA_V_1.2

2.2. Main circuit diagrams

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KEMPACT RA_V_1.2

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* Please refer to Kemppi Channel for the latest version of main circuit drawings !

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SERVICE MANUAL

3. DESCRIPTION OF OPERATIONS

Kempact RA welding machine consists of several circuit cards and separate components. In the following sections are
described the main components and separate cards functions.

Machine basic function (machine start up), after mains voltage is switched on:

1. DC-link capacitors are charged and if there is no over voltage condition inrush relay is switched on after a short delay

2. If there is PFC circuit it’s enabled after a short delay

3. Fans are started for a test run after a short delay

4. Welding is enabled

Kempact RA machines have following parts and components:

• Terminal block X001

• Varistors R001

• Main switch S001

• Terminal block X009

• Main circuit card Z001

o EMC filter
o Inrush current limiting
o IGBT driver
o Current transformer T1
o Main circuit

• PFC choke L002 (181-, 251-, 253MV- and 323MV-models)

• PFC circuit auxiliary transformer T003 (181-, 251-, 253MV- and 323MV-models))

• Test connector X006

• Auxiliary transformer T002

• Rectifier bridge G003

• Control card A001

• Cooling fans M001 and M002

• Gas valve Y001

• Wire feed motor M003

• Brights led card P002

• Panel card P001

• Main circuit card Z001

• Secondary rectifier card Z002

• Secondary choke L001

• Output RFI filters C001 and C002

• Euro connector X005

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KEMPACT RA_V_1.2

3.1. Main components

3.1.1. Terminal block X001

• Mains cable is connected to the terminal block X001. The terminal block is located in the mains cable connection box
on the back plate of the machine. Also varistors R001 are connected to this terminal block. From the terminal block
mains voltage is wired to main switch S001

3.1.2. Varistors R001

• The varistors are located in the mains cable connection box on the backside of the welding machine

• The purpose of the varistors is to protect the welding machine against voltage spikes coming from the mains

3.1.3. Main switch S001

• The main switch is located in the upper part of the machine close to the user interface

3.1.4. Terminal block X009

• From the main switch S001 mains voltage is wired to terminal block X009 which is located on the front side of the
component frame. From this terminal block mains voltage is wired to the main circuit card Z001

• PE (protective earth) is wired from this terminal block into the component frame and connected to a chassis ground
terminal

3.1.6. Test connector X006

• Possible to measure DC-link voltage during service

3.1.7. Auxliary transformer T002 and rectifier bridge G003

• Auxliary transformer is a 60VA toroidal transformer

• It has 230V and 400V inputs and 18V output

• 230V input is used in 181 and 251 machines

• 400V input is used in 253 and 323 machines

• Auxliary transformer output voltage is rectified using rectifier bridge G003. Both the auxiliary transformer and the

rectifier bridge are located inside the component frame

3.1.8. Control card A001

• All machines have different type of control card according machine size and type.

• MVU card has +24V aux power which regulates +24V when input voltage changes (+24V aux power components are

not installed on MVU control card).

3.1.8.1. Auxiliary power supply

• Auxliary voltage +24V is used by fans, gas valve, inrush relay and brights LED. This voltage is also used to drive opto­coupler that enables PFC and panel backlight. To generate +24V voltage auxliary transformer T002 output is full wave
rectified using rectifier bridge G003

• Auxliary voltage +15V is used by IGBT driver (V20, V22, V23, V25 etc.), PWM IC (N5), motor control half bridge driver
(N2) and other circuits

• Auxliary voltage +5V is used by microcontroller N7, panel card P001 and other circuits

3.1.8.2. Microcontroller

• Many of the control card A001 functions are using the microcontroller N7. Basic functions of the microcontroller
include controlling output voltage of the inverter. The microcontroller measures output voltage and changes peak
current reference of the inverter to regulate it

• The microcontroller also regulates wire feed speed by setting motor current reference and measuring EMF of the
motor

3.1.8.3. Motor control

• Wire feed motor control is based on EMF (electro magnetic force) measurement principle

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SERVICE MANUAL

• Wire feed mechanism doesn’t have tachometer, instead motor current is driven to zero every ca. 10ms and the EMF
of the motor is measured before motor current is increased again. This EMF information is then used to regulate
motor speed

• The microcontroller measures motor EMF and controls motor current to regulate motor speed

KEMPACT RA_V_1.2

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3.1.8.4. PWM

• PWM (pulse width modulation) circuit is for controlling the inverter

• Peak current-mode control is used to directly control primary current which is measured by current transformer T1 l

3.1.9. Fans M001, M002

• Machine fans are controlled by the control card A001 microcontroller. If there are two fans (3~models) in the ma­chine they are started in sequence so that second fan is started after 3s delay. When welding starts fans are started
and when welding stops fans are stopped after post run time

• In error situation fans are always on

• Fans are stopped if arc is not established during first 5s after start

3.1.10. Solenoid valve Y001

• Solenoid valve is controlled by control card A001 auxiliary voltage + 24 V

3.1.11. Wire feed motor M003

• Wire feed motor control is based on EMF (electro magnetic force) measurement principle. Wire feed mechanism
doesn’t have tachometer, instead motor current is driven to zero every ca. 10ms and the EMF of the motor is meas­ured before motor current is increased again. This EMF information is then used to regulate motor speed. Wire feed
motor speed control is done using the microcontroller. The microcontroller measures motor EMF and controls motor
current to regulate motor speed

• There is no special wire inch button. Wire inch is started like normal welding using the gun. When the user pushes
start button wire feed motor and the power source start. Wire feed speed is creep start speed which is slower than
normal wire feed speed. If arc is not established during first 5s the power source is shut down but wire feeding con­tinues with creep start speed for 30s. When the inverter is ON operating voltage for the wire feed motor is taken
from the output of the power source. When the inverter is SHUT DOWN after 5s operating voltage for the wire feed
motor is taken from the auxliary transformer for safety reasons. Because of this current limit of the wire feed motor
has to be lowered. For this reason also torque of the wire feed motor is reduced after 5s

3.1.12. Brights led card P002

• Controlled by control card A001 auxiliary voltage + 24 V

3.1.13. Panel card P001

• There is two panel versions R and A (R-version has limited functions). Panel is connected to the control card A001
with 16-wire ribbon cable

o When machine start up panel is showing power source size and SW version

3.1.14. Main transformer T001

• In the 181 and 251 machines the main transformer has 19 turn primary winding and center tapped secondary 2 + 2
turns (turns ratio 9.5:1)

• In the 253 machine the main transformer has 27 turn primary winding and center tapped secondary 2 + 2 turns
(turns ratio 13.5:1)

• In the 323 machine the main transformer has 25 turn primary winding and center tapped secondary 2 + 2 turns
(turns ratio 12.5:1)

3.1.15. Secondary rectifier card Z002

• Z002 is used to rectify the secondary current. There are 4 60A diodes connected in parallel in both legs of the rectifier
(V1 – V8) in 323 power source. 250 amps machine has 3+3 diodes

• Capacitors C1 and C2 and resistors R3 and R4 form a snubber circuit. The snubber circuit reduces the voltage stress of
the diodes caused by the reverse recovery current snap off

• Varistors R1 and R2 are for TIG ignition spark protection

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SERVICE MANUAL

• Operating voltage for the wire feed motor is rectified to capacitors C3-C5

KEMPACT RA_V_1.2

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3.1.16. Secondary choke L001

• The secondary choke L001 reduces ripple content of the secondary current

3.1.17. Output RFI filter C001, C002

• Capacitors C001 and C002 connected to the dowel screws (+ and -) reduce radio frequency interference

3.1.18. Output terminal X004

• Dix connector X004

3.1.19. Euro connector X005

3.2. Main circuit diagram 181-, 251-models

• 181 and 251 machines have many common technical details with 253 and 323 machines. They have e.g. the same
A001, P001, P002 and Z002 cards. Main differences to 253 and 323 machines are described here

3.2.1. PFC Choke L002

181 and 251 machines include PFC (Power Factor Correction) circuit. This is implemented using boost topology. The Boost to­pology has choke in the input side of the converter. In Kempact 181 and 251 this choke is located on the front side of the com­ponent frame from where it is wired into the component frame

3.2.2. PFC circuit auxiliary transformer T003

PFC circuit auxiliary power is generated using small toroidal transformer located inside the component frame

3.2.3. Main circuit card Z001

3.2.3.1. EMC Filter

• Capacitors C7, C10, C15, C16 and inductor T6 form an EMC filter. The purpose C17 and R18 is to dampen common
mode transients coming from mains

3.2.3.2. Inrush current limiting

• PTC resistors R16 and R17 limit inrush current when the power source is switched on. PTCs are bypassed with relays
K1 and K2 after DC link capacitors have been charged. Relays K1 and K2 are controlled by the microcontroller

3.2.3.3. IGBT driver

• IGBT driver consists of gate transformers T2 and T3 and surrounding components

3.2.3.4. Current transformer T1

• Current transformer T1 is monitoring primary current and stops power stage operation if current is raising too high

3.2.3.5. Main circuit

• The main circuit consists of boost type PFC circuit followed by H-bridge type converter.

• Both parts of the main circuit are implemented using the same 600V, 75A six pack IGBT module

• One leg of the IGBT module is used for the Boost PFC circuit. Lower IGBT is used as the Boost power switch and the

anti-parallel diode of the upper IGBT as the boost diode

• The switching frequency of the boost circuit is ca. 15 kHz. The boost circuit raises DC link voltage to ca. 370V. Boost
input current is measured using shunt resistors R58, R59, R65, R66. H – bridge is implemented using the other two
legs of the IGBT module

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SERVICE MANUAL

G1

G3

G2

G4

U

U

G2

U

T1

G5

L1

U

U

U

U

U

U

U

Approx .. + 57

0 V

KEMPACT RA_V_1.2

3.2.3.6. PFC Boost control circuitry

• PFC control circuitry is located on the primary side. Auxliary transformer T003 supplies operating voltage for the PFC
control circuitry. The output voltage of the T003 is first rectified and then linear regulator is used to regulate auxiliary
voltage to 15V. PFC control IC N1 regulates DC-link voltage to approximately 370V

3.3. Main circuit diagram 253-, 323-models

3.3.1. Main circuit card Z001

3.3.1.1. EMC filter

• Capacitors C5 - C7, C8 - C10, C19 - C21 and inductors T4 and L1 form an EMC filter

• First part of the filter is three phase filter which is located before the three phase rectifier V2

• Second part is DC filter (L1) which is located after three phase rectifier

3.3.1.2. Inrush current limiting

• PTC resistor R1 limits inrush current when the power source is switched on

• R1 is bypassed with relays K1 and K2 after DC link capacitors C17, C18 have been charged

• Relays K1 and K2 are controlled with the microcontroller

3.3.1.3. IGBT driver

• IGBT driver consists of gate transformers T2 and T3 and surrounding components

3.3.1.4. Current transformer T1

• Current transformer T1 is monitoring primary current and stops power stage operation if current is raising too high

3.3.1.5. Main circuit

• Main circuit topology is H-bridge. The H-bridge topology requires four power switches which are implemented using
IGBT module V2. The switching frequency of the H – bridge is 20 kHz

• 253 power source uses 50A module

• 323 power source uses 75A module

G1

16 (40)

G1

G3

G2

T1

G4

When IGBT-transistors G1 and G4 conduct, there is a positive voltage U

transistors G2 and G3 conduct there is a negative voltage U

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IGBT timings (PWM).

G3

U

G5

G4

L1

U

U

G5

U

L1

in main transformer T1 primary and when IGBT-

in main transformer primary. Power is adjusted by changing the

T1

T1

SERVICE MANUAL

KEMPACT RA_V_1.2

17 (40)

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SERVICE MANUAL

KEMPACT RA_V_1.2

3.4. Main circuit diagram 253MV-, 323MV-models

3.4.1. General

• 323 MV and 253 MV machines have many common technical details with the 323 and 253 machines. They have e.g.
the same Z002, A001 and P001 cards. Also main transformers are same. Main difference is of course that they are
multi voltage machines. This means that these machines can be connected to any mains voltage between 230V -15%­400V +15%. The selection of input voltage is automatic. In fact, the multi voltage machines use basically the same
technology as the one phase machines. This means that there is first a boost type converter which raises rectified in­put voltage to approximately 630V DC-link voltage. This DC-link voltage is then used as input voltage for the H-bridge.
So PFC boost is used as an input stage for the H-bridge. Regardless of input voltage (230V -15% - 400V +15%) boost
stage raises DC-link voltage to same value so the input voltage to the H-bridge stays the same.

3.4.2. Main circuit card Z001

3.4.2.1. EMC filter

• Capacitors C5 – C10 and inductor T6 forms an EMC filter

3.4.2.2. Inrush current limiting

• PTC resistor R70 limits inrush current when the power source is switched on

• PTC is bypassed with relays K1 and K2 after DC link capacitors have been charged

• Relays K1 and K2 are controlled with the microcontroller

3.4.2.3. IGBT driver

• IGBT driver consists of gate transformers T2 and T3 and surrounding components

3.4.2.4. Current transformer T1

• Current transformer T1 is monitoring primary current and stops power stage operation if current is raising too high

3.4.2.5. Main circuit

• The main circuit consists of boost type PFC circuit followed by H-bridge type converter.

• Both parts of the main circuit are implemented using the same 1200V, 100A six pack IGBT module

• One leg of the IGBT module is used for the Boost PFC circuit. Lower IGBT is used as the Boost power switch and the

anti-parallel diode of the upper IGBT as the boost diode. H – bridge is implemented using the other two legs of the
IGBT module

• The switching frequency of the boost circuit is ca. 13 kHz. The boost circuit raises DC link voltage to ca. 630V. Boost
input current is measured using shunt resistors R58, R59, R65, R66.

• The operation of the H-bridge is the same as with the 323 and 253 machines.

3.4.2.6. PFC Boost control circuitry

• PFC control circuitry is located on the primary side. Auxliary transformer T003 supplies operating voltage for the PFC
control circuitry. The output voltage of the T003 is first rectified and then linear regulator is used to regulate auxiliary
voltage to 15V. PFC control IC N1 regulates DC-link voltage to approximately 630V.

18 (40)

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SERVICE MANUAL

X2 Mains voltage

Mains voltage connector

Pin Signal

KEMPACT RA_V_1.2

4. MAIN CIRCUIT CARD Z001

4.1. Kempact 181, 251

19 (40)

4.1.1. Connectors

Pin Signal Description
X1 Mains voltage Main voltage connector

Pin Signal
X4 Chassis ground connector

X5 Auxiliary transformer connection, auxliary transformer is protected with PTC resistors R63 and R64
X6 PFC Auxiliary transformer connection, auxliary transformer is protected with PTC resistors R63 and R64

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SERVICE MANUAL

X7 Main transformer connections

Pin Signal

Description

X10:4

Inrush Relay

Other end of the

inrush relay coil

X10:8 PFC ON/OFF P

PFC on/off opto coupler

diode positive end

X10:9 - -

X10:12 - -

X11

PFC choke connections

X12

PFC choke connections

X14 PFC

choke connections

X13 DC-link voltage

X16 DC-link voltage

Pin Signal

X8 Main transformer connections
X17 Main transformer connections
X19 Main transformer connections

Pin Signal
X9 PFC auxiliary voltage connector

X10:1 Inrush Relay Other end of the inrush relay coil
X10:2 OV Opto P Over voltage optocoupler other end
X10:3 Primary current transformer Primary current transformer other end

X10:5 OV Opto N Over voltage optocoupler other end
X10:6 Primary current transformer Primary current transformer other end
X10:7 IGBT Drive B Other end of the IGBT driver transformer primary

KEMPACT RA_V_1.2

20 (40)

X10:10 IGBT Drive A Other end of the IGBT driver transformer primary
X10:11 PFC ON/OFF N PFC on/off opto coupler diode negative end

Pin Signal

X15 PFC choke connections

Pin Signal

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SERVICE MANUAL

Pin Signal

Description

X2 Mains voltage

Main

s voltage

connector

X3 Mains voltage

Mains voltage

connector

Pin Signal

X5 Auxiliary transformer connection

, auxliary transformer is protected with PTC resistors R16 and R17

X7 Main transformer connections

(253 machine use two flat connectors, 323 use four)

X8 Main transformer connections

(253 machine use two flat connectors, 323 use four)

KEMPACT RA_V_1.2

4.2. Kempact 253, 323

21 (40)

4.2.1. Connectors

X1 Mains voltage Main voltage connector

Pin Signal
X4 Chassis ground connection

Pin Signal

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SERVICE MANUAL

X9:2 OV Opto P

Over voltage optocoupler other end

X9:6 Inrush Relay

Other end of the inrush relay coil

KEMPACT RA_V_1.2

X13 Main transformer connections (253 machine use two flat connectors, 323 use four)
X14 Main transformer connections (253 machine use two flat connectors, 323 use four)

Pin Signal Description
X9:1 IGBT Drive B Other end of the IGBT driver transformer primary

X9:3 Inrush Relay Other end of the inrush relay coil
X9:4 IGBT Drive A Other end of the IGBT driver transformer primary
X9:5 OV Opto N Over voltage optocoupler other end

Pin Signal
X10 Primary current transformer connector

Pin Signal
X11 DC-link voltage
X12 DC-link voltage

22 (40)

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SERVICE MANUAL

Pin Signal

Description

X2

, X21 Mains voltage

Mains voltage connector

X3, X22

Mains voltage

Mains voltage connector

Pin Signal

Description

X5

Auxliary transformer connectors. Auxliary transformer is protected with PTC resistors R63 and R64.

KEMPACT RA_V_1.2

4.3. Kempact 253MV, 323MV

23 (40)

4.3.1. Connectors

X1, X9 Mains voltage Main voltage connector

Pin Signal
X4 Chassis ground connection

X6 Auxliary transformer connectors. Auxliary transformer is protected with PTC resistors R63 and R64.

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SERVICE MANUAL

X13 Main trans

former connections (253 machine use two flat connectors, 323 use four)

X10:2 - -

X10:6

Primary current transformer

Primary current transformer other end

Pin Signal

X18:2

PFC ON/OFF P

PFC on/off opto coupler diode positive end

X18:6

OV Opto N

Over voltage optocoupler other end

Pin Signal
X7 Main transformer connections (253 machine use two flat connectors, 323 use four)
X8 Main transformer connections (253 machine use two flat connectors, 323 use four)

X17 Main transformer connections (253 machine use two flat connectors, 323 use four)

KEMPACT RA_V_1.2

Pin Signal Description
X10:1 Inrush Relay Other end of the inrush relay coil

X10:3 Primary current transformer Primary current transformer other end
X10:4 Inrush Relay Other end of the inrush relay coil
X10:5 - -

Pin Signal
X11 PFC choke connections
X12 PFC choke connections

Pin Signal
X14 PFC choke connections
X15 PFC choke connections

24 (40)

X16 PFC-auxiliary voltage connector

Pin Signal Description
X18:1 IGBT Drive B Other end of the IGBT driver transformer primary

X18:3 OV Opto P Over voltage optocoupler other end
X18:4 IGBT Drive A Other end of the IGBT driver transformer primary
X18:5 PFC ON/OFF N PFC on/off opto coupler diode positive end

Pin Signal
X19 DC-link voltage
X20 DC-link voltage

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SERVICE MANUAL

X1 Main transformer secondary

X5 Rectified +24V

KEMPACT RA_V_1.2

5. SECONDARY RECTIFIER CARD Z002

25 (40)

5.1. Connectors

Pin Signal

X2 Main transformer secondary
X3 Z002 card connection to secondary profile
X4 Z002 card connection to secondary profile

X6 Polarity connector (-)

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SERVICE MANUAL

Led Description

X2:2 GND Ground

X2:3 + 24 V

+24V from the auxiliary transformer

X2:6 GND G

round

KEMPACT RA_V_1.2

6. CONTROL CARD A001

26 (40)

6.1. Leds

H1 Auxiliary voltage + 15V
H2 Status of IGBT driver, when this LED is lit IGBT driver is active
H4 RDI debug purposes
H5 Motor control input voltage
H6 +24V voltage

6.2. Connectors

Pin Signal Description
X2:1 + 50 V Secondary voltage from secondary card

X2:4 Motor (+) Wire feed motor (+)
X2:5 Motor (-) Wire feed motor (-)

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SERVICE MANUAL

X3:3 CT (A)

Current transformer secondary (A)

X3:7 GND G

round

X3:11 J1 Machine type jumper J

1

X4:1 Fan1 (

-)

Fan 1 (

-)

X4:2 Fan2 (

-)

Fan 2 (

-)

X4:5 Fan2 (+)

Fan 2 (+)

X4:6 Gas Valve

Gas valve

X4:9 Inrush relay

Inrush relay connection

X4:10 Brights led (

-)

Brights led card (P002) (

-

) connection.

X4:12 Inrush relay

Inrush relay connection

Pin Signal

Description

Pin Signal

Description

X6:1 PWM drive B

IGBT driver transformer other end

X6:4 PWM drive A

IGBT driver transformer other end

X6:5 PTC PTC connection

X7 Connections to chassis ground

Pin Signal

Pin Signal

X10 Maintenance use

Pin Signal

X16 Panel card P001 connection

X19 Not in use

Pin Signal Description
X3:1 Vout Output voltage measurement from the dowel screw (+)
X3:2 CT (B) Current transformer secondary (B).

X3:4 GND Ground
X3:5 GND Ground
X3:6 J3 Primary current limit jumper.

X3:8 GND Ground
X3:9 GND Ground
X3:10 J2 Machine type jumper J2

X3:12 J0 Machine type jumper J0

Pin Signal Description

X4:3 Gas Valve Gas valve
X4:4 Fan1 (+) Fan 1 (+)

KEMPACT RA_V_1.2

27 (40)

X4:7 Brights led (+) Brights led card (P002) (+) connection.
X4:8 PFC control (+) PFC ON/OFF control (+) connection

X4:11 PFC control (-) PFC ON/OFF control (-) connection

X5:1 PRIM_OV_P Primary over voltage alarm (+)
X5:2 PRIM_OV_N Primary over voltage alarm (-)

X6:2 PTC gnd PTC ground connection
X6:3 Start B Gun switch connection

X6:6 Start A Gun switch connection

Pin Signal

X8 Used in development purposes, do not connect anything here

Pin Signal

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SERVICE MANUAL

Pin Signal

Description

X1:4 GND Ground

X1:8 Pot

_1_B Pulse potentiometer 1 channel B

X1:9 GND Ground

X1:12 GND Ground

X1:13 Pot

_3_A Pulse potentiometer 3 channel A

X1:16 +24V +24V supply voltage for the

LCD backlight

KEMPACT RA_V_1.2

7. PANEL CARD P001

• Panel card is connected to the control card A001 connector with 16-wire ribbon cable

7.1. Connectors

X1:1 +24V +24V supply voltage for the LCD backlight
X1:2 SDA I2C bus data
X1:3 +5V +5V supply voltage

X1:5 SCL I2C clock
X1:6 GND Ground
X1:7 Pot_1_A Pulse potentiometer 1 channel A

X1:10 Pot_2_A Pulse potentiometer 2 channel A
X1:11 Pot_2_B Pulse potentiometer 2 channel B

28 (40)

X1:14 Pot_3_B Pulse potentiometer 3 channel B
X1:15 +5V +5V supply voltage

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SERVICE MANUAL

V24,25

V1

KEMPACT RA_V_1.2

29 (40)

8. OPERATIONAL MEASURINGS AND TESTS

NOTE !
Main supply voltage must not be connected when making measuring operations. The component frame has to be uninstalled
so that main components conditions can be measured.

8.1. Kempact 181, 251

8.1.1 Primary rectifier V24, 25

• Primary side primary rectifier diodes can be measured one at the time

• Diodes must be measured both forward bias and reverse bias condition to make sure they are fine

• Check the diodes using the multimeter diode function to measure their threshold voltage 0,3…0,6 V

Measurings :

1) Positive test pole to rectifier pole (1, red), negative test pole to rectifiers poles (1, black) one at time
Result: 0,3…0,6diodes Ok

2) Negative test pole to rectifier pole (2, black), positive test pole to rectifier poles (2, red) one at the time
Result: no valuediodes Ok

3) Negative test pole to rectifier pole (3, black), positive test pole rectifier poles (2, red)one at the time
Result: 0,3…0,6diodes Ok

4) Positive pole to rectifier pole (4, red), negative test pole to rectifier poles (1, black) one at the time
Result: no valuediodes Ok

NOTE !
The measurement procedure is same for V24 and V25 rectifiers.

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SERVICE MANUAL

KEMPACT RA_V_1.2

30 (40)

8.1.2. IGBT module V1

• IGBT module can be tested by multimeter if using the diode tester function. Module holds six diodes and in many
cases they may be defective if IGBT is damaged

• When measuring IGBT unit diodes you must disconnect other end of main transformer (X7)

o After measuring connect other end (X7) back

Measurings:

1) Positive test pole (1, red) to connector X16, negative test pole (1, black) to connectors X7, X8 and X14 one at time
Result: 0,3…0,6diodes Ok

2) Negative test pole (2, black) to connector X13, positive test pole (2, red) to connectors and X7, X8 and X14 one at time
Result: 0,3…0,6diodes Ok

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SERVICE MANUAL

V1 V2

KEMPACT RA_V_1.2

8.2. Kempact 253, 323

31 (40)

8.2.1. Primary rectifier, V1

• Primary side primary rectifier diodes can be measured one at the time

• Diodes must be measured both forward bias and reverse bias condition to make sure they are fine

• Check the diodes using the multimeter diode function to measure their threshold voltage 0,3…0,6 V

Measurings:

1) Positive test pole to DC-link (-), negative test pole to L1, L2, L3 (one at the time)
Result: 0,3…0,6diodes Ok

2) Positive test pole to DC-link (+), negative test pole L1, L2, L3 (one at the time)
Result: no valuediodes Ok

3) Negative test pole to DC-link (+), positive test pole L1, L2, L3 (one at the time)
Result: 0,3…0,6diodes Ok

4) Negative test pole to DC-link (-), positive test pole L1, L2, L3 (one at the time)
Result: no valuediodes Ok

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SERVICE MANUAL

KEMPACT RA_V_1.2

8.2.2. IGBT module, V2

• IGBT module can be tested by multimeter if using the diode tester function. Module holds four diodes and in many
cases they may be defective if IGBT is damaged

• When measuring IGBT unit diodes you must disconnect other end of main transformer (X7)

o After measuring connect other end (X7) back

Measurings:

1) Positive test pole to connector X7 and X8 one at time, negative test pole to DC link (+)
Result: 0,3…0,6diodes Ok

2) Positive test pole to DC-link (-), negative test pole to X7 and X8 one at time
Result: 0,3…0,6diodes Ok

32 (40)

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SERVICE MANUAL

V31 V1

(+)

(-)

1

1)

2)

2)

2)

2)

1)

1)

1) 1)

2) 2) 2)

1

3)

3)

KEMPACT RA_V_1.2

8.3. Kempact 253MV, 323MV

33 (40)

8.3.1. Primary rectifier, V31

• Primary side primary rectifier diodes can be measured one at the time

• Diodes must be measured both forward bias and reverse bias condition to make sure they are fine

• Check the diodes using the multimeter diode function to measure their threshold voltage 0,3…0,6 V

Measurings :

1) Negative test pole to rectifier pole (1, black), positive test pole to rectifiers poles (1, red) one at time
Result: 0,3…0,6diodes Ok.

2) Positive test pole to rectifier pole (3, red), negative test pole to rectifier poles (2, black) one at the time
Result: no valuediodes Ok

3) Positive test pole to rectifier pole (2, red), negative test pole rectifier poles (2, black)one at the time
Result: 0,3…0,6diodes Ok

4) Negative test pole to rectifier pole (3, black), positive test pole to rectifier poles (2, red) one at the time
Result: no valuediodes Ok

)

1)

3)

)

Kemppi Oy

2)

3)

SERVICE MANUAL

1)

1)

1)

2)

1)

2)

2)

2)

1)

2)

2)

KEMPACT RA_V_1.2

34 (40)

8.3.2. IGBT module, V1

• IGBT module can be tested by multimeter if using the diode tester function. Module holds six diodes and in many
cases they may be defective if IGBT is damaged

• When measuring IGBT unit diodes you must disconnect other end of main transformer (X7)

o After measuring connect other end (X7) back

Measurings:

1) Negative test pole (1, black) to connector X19, positive test pole (1, red) to connectors X13, X14 and X17 one at time
Result: 0,3…0,6diodes Ok

2) Positive test pole (2, red) to connector X20, negative test pole (2, black) to connectors and X13, X14 and X17 one at time
Result: 0,3…0,6diodes Ok

1)

1)

2)

1)

2)

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SERVICE MANUAL

8.4. Secondary rectifier card, Z002

• Use a digital multimeter to test the secondary unit diodes. Diodes are in groups, so you can measure them in two
separate groups

KEMPACT RA_V_1.2

35 (40)

Measurings:

1) Positive test pole to main transformer secondary (secondary card connectors X1 and X2 one at time), negative test pole to
secondary profile
Result: 0,3…0,6diodes Ok

2) Positive test pole to secondary profile, negative test pole to main transformer secondary (secondary card connectors X1 and
X2 one at time)
Result: no valuediodes Ok

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SERVICE MANUAL

KEMPACT RA_V_1.2

36 (40)

3) Snubber resistors R3 and R4
Result: value ~10 Ω

8.5. PTC’s, overheat protection

• There are two PTC’s in machine

o Main transformer Rt101 140 °C, value ~94 Ω in room temperature (connector 12, blue/white)
o Secondary profile Rg201 90 °C, value ~63 Ω in room temperature (connector 11, green/green)
o In over temperature situation PTC goes to high-resistance mode (>10kΩ)
o A broken PTC has usually hundreds of kilo ohms resistance or no value at all

8.6. Control card A001

• Control card voltages can be quickly verified with LEDs on the control card A001

9. MAIN COMPONENTS INSTALLATION

• Heat sink paste should be spread on to the modules in an even layer by using clean fingers. Then the card should be
immediately mounted onto the heat sink, this minimizes the possibility of any contamination (dirt etc.) getting
between the components.

• Use torque screwdriver when tightening any power components onto the heat sink. See following sections for
tightening torques.

9.1. Main circuit card Z001

• Primary rectifier V1 to heatsink 2 NM

• IGBT unit to heatsink

o First step 2 NM and wait a couple minutes
o Second step 3 NM

• Main circuit card Z001 to profile holder 0,7 NM

• Primary unit to component frame 2 NM

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SERVICE MANUAL

• Z001 grounding cable to component frame 5 NM

KEMPACT RA_V_1.2

9.2. Secondary rectifier card Z002

• Secondary diodes to heatsink 1,2 NM

• Resistors to heatsink 0,7 NM

• Secondary card Z002 to heatsink 2,5 NM

• Secondary profile to component frame 2 NM

• Main transformer secondary leads 5 NM

9.3. Other components

• Main transformer T001 to component frame 2 NM

• Main transformer T001 secondary leads to secondary card Z002:X1,X2 5 NM

• Rectifier G003 to component frame 5 NM

• Auxiliary transformer T002 to component frame 5 NM

• Secondary choke L001 to component frame 2 NM

• Secondary choke L001 other lead to secondary profile 5 NM and other lead to polarity screw 5 NM

37 (40)

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SERVICE MANUAL

2 Mai

ns under voltage

-m

ains voltage is under

lower

limit.

-check mains voltage

7 User interface memory error

-EEPROM memory error

-

start up machine (on/off)

9 Memory channel 2 error

-memory channel data is invalid / corrupted

-start up machine (on/off)

102 Microcontroller error

-microcontroller reset. Possible reason: ele

c-

-

start up machine (on/off)

112 Panel communication error

-communication error between panel card

-

check flat cable/connectors between

KEMPACT RA_V_1.2

10. ERROR CODES

• In error situation welding is stopped and an error code is displayed on the panel

• The user can clear the error by pressing any of the panel buttons and if certain conditions are fulfilled

• If there are multiple errors at the same time only one can be displayed at a time. After user has cleared one error

next is displayed and so on until there is no more errors

Error code Error Reason Action / remedy

38 (40)

-181 model: 195 V

-251 model: 204 V

-253, 323 models: 340V

3 Mains over voltage -mains voltage is over high limit:

-181 model: 265 V

-251 model: 276 V

-253, 323 models: 460V

4 Wire feed motor over current -wire feed motor current (6 amps longer

than 60 s) is too high

-motor is jammed longer than 60 s

5 Wire feed motor control not

calibrated

6 Power source control not

calibrated

8 Memory channel 1 error -memory channel data is invalid / corrupted -start up machine (on/off)

10 Memory channel 3 error -memory channel data is invalid / corrupted -start up machine (on/off)

11 Memory channel 4 error -memory channel data is invalid / corrupted -start up machine (on/off)

12 Continuous short circuit in the out-

put of the power source

100 Microcontroller error -microcontroller reset. Possible reason: tig

101 Microcontroller error -microcontroller reset. Possible reason:

-calibration parameters have been corrupted

-faulty control card A001

-power source control calibration parame­ters are not in predefined limits

-calibration parameters have been corrupted

-faulty control card A001

-used wrong welding parameters (improper
value)

-there is continuous (over 2s.) short circuit in
the output of the power source.

ignition spark.

flash memory has been corrupted

-mains over voltage error can be
cleared after mains voltage has risen
over low limit.

-check mains voltage

-mains over voltage error can be
cleared after mains voltage has fallen
under high limit

-this error can be cleared after weld­ing has stopped due to this error

-check wire feeding motor and mech­anism

-start up machine (on/off)

-change control card A001

-start up machine (on/off)

- change control card A001

-check welding parameters

-check welding parameters

-check welding parameters

-check welding parameters

-check welding parameters

-remove short circuit from machine
output (contact tip is connected /
short circuited in welding piece)

-start up machine (on/off)

-start up machine (on/off)

103 Microcontroller error -microcontroller reset. Possible reason: elec-

110 Panel communication error -communication error between panel card

111 Panel communication error -communication error between panel card

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tromagnetic disturbance

tromagnetic disturbance

P001 and control card A001

P001 and control card A001

P001 and control card A001

-start up machine (on/off)

-check flat cable/connectors between
panel- and control card

-check flat cable/connectors between
panel- and control card

panel- and control card