Kemppi FitWeld 300 Manual de usuario

Service manual

Fitweld 300

Version 1.2

Technical data

4 x 1,5 mm² 5 m) / 10 A delayedConnection cable / fuse

Filler wires 0,8 – 1,2 mm

0,8 – 1,2 mm

1,0 – 1,2 mm

Fe solid

Fe cored

14,5 KgWeight

External dimensions L x W x H) 457 x 226 x 339 mm

200mm

Spool, max ø

0,85MIGEfficiency at max. current

0,95MIGPower ratio at max. Current

43 VOpen circuit voltage

20 A / 11 V – 300 A / 32 VMIGWelding range

300 A / 29 V

220 A / 25 V

180 A / 23 V

140 A / 21 V

Max. 11 kVA

3~400 V -15%/+10%, 50 / 60 Hz

ED 20%

ED 40%

ED 60%

ED 100%

MIG

Load capacity 40 °

°°

°C

Rated power

Supply voltage

The device may be repaired only by a person legally authorized

perform electric work!

User interface 2

1. Welding voltage adjustment

2. Wire feeding adjustment

3. ON signal lamp

4. Overheat protection lamp

5. No gas warning lamp

6. Euro connector

Front Plate

Back Plate

7. Gas connector

8. Main switch

9. Ground cable connector

12 10 11

Spool room

10. 2T no gas/2T/4T switch

11. Gas flow adjustment

12. Spool room light

13. Polarity selection

Construction

Z002

Z001

P001

A001

Gas valve

Wire feeder

motor

Cooling

fans

Gas pressure

switch

Gas flow

adjustment

Tip

If machines cover plate screws thread fails you could

change PT screws diameter to 5,5mm - 6mm.

Note!

Protective earth conductivity test must be performed at

earth points on both the front and back plates

Main circuit diagram

Main circuit card Z001

IGBT-moduleCurrent transformer

EMC filtering

Primary rectifier

Gate transformers

- EMC filtering

- Primary rectifier and DC -link charging PTC

- H –bridge frequency 27kHz)

- Gate transformers and gate drivers

- Auxiliary voltage 15VDC

- Over voltage sensing from DC-link

- Two stage fan start

- PTC protection alerts signals comes from the main transformer and the

secondary choke)

Functions and components:

15VDC aux. voltage

indicator LED

Jumpers, default settings:

X25 open

X26 closed,

- generator compensation off

X27 open

X28 closed

X29 closed

X32 open

X28

X26

X25

X27

X29

X32

Main circuit card Z001

Measurement points

DC Link -

DC Link +

L1,L2 and L3

DC-link voltage with Kemppi multipower):

digital multimeter

1. Feed 22 VAC to auxiliary transformers secondary

connector from Kemppi multipower connector

must be connected)

2. Measure value from DC-link test points by digital

multimeter

Value: 500 VDC or more

3. Measure secondary voltage start signal needed)

Value: 30VDC or more

Primary rectifier: Digital multimeter diode

test

1. Red test probe L1, L2, and L3 one at the

time)

Black test probe DC-link plus

Value: 0,3 - 0,5 VDC -> diodes ok

2. Red test probe DC-link plus

Black test probe L1,L2 and L3 one at the

time)

Value: No value -> diodes ok

3. Red test probe L1, L2, and L3 one at the

time)

Black test probe DC-link minus

Value: No value -> diodes ok

4. Red test probe DC-link minus

Black test probe L1,L2 and L3 one at the

time)

Value: 0,3 – 0,5 VDC -> diodes ok

If values in test 1 or 4 are close to zero rectifier is

short circuited. If value is “no value” circuit is

open

If values in test 2 or 3 are close to zero diodes are

leaking

Auxiliary

transformers

secondary

connector

Secondary rectifier Z002

Measurement points

Diode branch A

Diode branch B

Common point

Resistor A

Resistor B

Secondary diodes:

1. Measure diode branches one at the time

from transformer red test probe) to

common point black test probe)

Values: 0,3 – 0,5 VDC

2. Measure diode branches one at the time

from common point red test probe) to

transformer black test probe)

Value: No value

Damping circuit resistors:

Resistor value must be 5Ω

Main components

- Middle point connected full wave rectifier

- Damping circuit reduces voltage stress of diodes

- Overvoltage varistors protect diodes from ignition sparks

Wire feeder motor control card A001

Adjustments

Wire feed speed maximum:

1. Adjust wire feed speed potentiometer to

maximum

2. Feed wire 10 second by triggering the

torch

3. Measure fed wire length

4. Should be 16,7% of 18m/min 3m/min)

- If wire feed speed is offset, adjust

trimmer and repeat steps 2.-4.

Functions

- Wire motor power feeding from machine’s secondary circuit by MOSFET half bridge

- Wire feed speed maximum adjustment by trimmer

- Spool room light in different small card)

Tilt and detach

NOTE!

- When installing spare part card you have to check wire feeding speed maximum adjustment level

- Before installing tilt and detach spool room light card

Panel card P001

Functions

- Supply voltage 24VDC filtering

- Generating reference voltage 3,3VDC

- Voltage adjustment by potentiometer

- Wire feed adjustment by potentiometer

- Start signal throughput for optional usage)

- Three leds: On, Overheat protection and No gas

Gas pressure switch S002

Functions

- Prevent welding while gas pressure under adjusted level

- Adjusted to 1 bar as a default

- Not functioning in gasless wire mode

Adjustment

1. Connect gas hose to gas connector

2. Adjust pressure to 1 bar

3. Adjust pressure switch alert level to 1 bar

Alert level adjustment

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