Download Main circuit diagram - Rapid Welding and Industrial Supplies Ltd
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Service manual v. 1.0 FastMig KM 300 KMS 300 KM 400 KMS 400 KM 500 KMS 500 MF 29 MF 33 MSF 53 MSF 55 MSF 57 1 Table of contents Technical data Fastmig KM / MF............................................................................. 3 FastMig KMS / MFS........................................................................ 4 Fastmig KMS / MVU........................................................................ 5 Main circuit diagram KM.................................................................................................... 6-7 MF.................................................................................................... 8 KMS................................................................................................. 9 MSF................................................................................................. 10 KM / MVU........................................................................................ 11 KMS / MVU..................................................................................... 12 Block diagram.................................................................................................... 13 Main circuit card Z001 KM / KMS Operating diagram........................................................................... 14 Operation principle.......................................................................... 15 Connectors...................................................................................... 16 Operational measurings.................................................................. 17 Capacitor card Z002 Operating diagram.......................................................................... 18 Connectors..................................................................................... 18 Secondary rectifier card Z003 Operating diagram.......................................................................... 19 Connectors..................................................................................... 19 Operational measurings................................................................. 19 Control card A001 Operating diagram.......................................................................... 20 Connectors..................................................................................... 21-22 Operation of the LEDs on control card........................................... 22 Motor control card A002 Operating diagram.......................................................................... 23 Connectors..................................................................................... 24 ID-chip card A002 (MSF) Connectors..................................................................................... 25 Panel card P001 Operating diagram.......................................................................... 26 Connectors..................................................................................... 26 Error codes........................................................................................................ 27 Setup menu....................................................................................................... 28 Wire feed speed calibration / KM.................................................................... 29-30 Structure KM / KMS....................................................................................... 31-32 MF.................................................................................................. 33 MFS................................................................................................ 34 IGBT testing....................................................................................................... 35 IGBT replacing................................................................................................... 36 2 Technical data FastMig KM / MF 3 Technical data FastMig KMS / MSF 4 Technical data FastMig KMS / MVU 5 Main circuit diagram L001 Choke R001 Varistors Z002 Z001 Capasitor card Main circuit card S001 Main switch PTC T001 Main transformer PTC Z003 Secondary card PTC L001 RC001 Secondary choke RC-protection G003 Diode bridge T002 Aux. transformer M001 Cooling fan A001 Control card F001 Fuse 6,3 A H001 / 002 Leds A002 Control card P001 Panel card KM-power sources (A002) also contain circuitry that is needed for wire feeding motor driving and reading of the potentiometer of the simple wire feeder (MF or other). 6 Main circuit diagram KM 7 Main circuit diagram MF 8 Main circuit diagram KMS 9 Main circuit diagram MSF 10 Main circuit diagram KM / MVU 11 Main circuit diagram KMS / MVU 12 Block diagram Control card A001 •Microcontroller •PWM circuit •Secondary voltage measurement •Secondary current measurement •IGBT driver •Auxiliary device connection •Auxiliary power supply •Machine size jumpers(J1, J2) •Primary current limit jumpers(J3, J4, J5) •Operational jumpers •LED’s •Water cooler connection Control card A002 •WF-motor control •Connection to the panel card P001 •Remote controller connection •MIG gun connection •Solenoid valve connection •Fuse Panel card P001 •Main micro controller •User interface (buttons, potentiometers, displays, LED’s) •Connection to the A002 Main circuit card Z001 •EMI filtering •Three phase rectifier (V6) •Switching-ON transient suppression •Power Stage •Current transformer (T1) Capasitor card Z002 •Energy storage •Discharging Secondary card Z003 •Rectifying •Snubber •Protection against HF 13 Main circuit card Z001 KM / KMS DC-link (+) IGBT gates From main switch Main transformer primary coil DC-link (-) Operating diagram - EMI filtering - Three phase rectifier (V6) - Switching-ON transient suppression - Power Stage - Current transformer (T1) 14 Main circuit card Z001 Operation principle Approx.. + 570 V G1 UG1 G2 G5 UG2 UT1 L1 UG5 G3 UG3 UL1 G4 UG4 UG1 UG2 t t UG3 UG4 UT1 t t t UG5 UL1 t t When IGBT-transistors G1 and G4 conduct, there is a positive voltage UT1 in main transformer T1 primary and when IGBT-transistors G2 and G3 conduct there is a negative voltage UT1 in main transformer primary. Power is adjusted by changing the IGBT timings (PWM) 15 Main circuit card Z001 Connectors X19 X21 X15 X14 X11 X10 X13 X12 X9 X8 X20 X18 X40 X41 X29 X6 X37 X36 X7 X17 X16 X3 X2 X4 X1 X2 X3 X4 X5 X6 X7 X8 X9 X10 X11 X12 X13 X14 X15 Z001 connectors / signals Main switch Main switch Main switch Chassis ground Chassis ground Main transformer Main transformer IGBT gates and emitters IGBT gates and emitters IGBT gates and emitters IGBT gates and emitters IGBT gates and emitters IGBT gates and emitters IGBT gates and emitters IGBT gates and emitters X16 X17 X18 X19 X20 X21 X29 X36 X37 X40 X41 X1 X5 Z001 connectors / signals Primary choke Primary choke DC-link voltage (+) DC-link voltage (+) DC-link voltage (-) DC-link voltage (-) Chassis ground Current transformer secondary Current transformer secondary Auxiliary transformer Auxiliary transformer 16 Main circuit card Z001 Operational measurings A B A. Main transformer T001 primary voltage, set values 50 A/16,5 V B. IGBT-gate pulses, set values 50 A/16,5 V 17 Capacitor card Z002 Operating diagram X3 X1 - Energy storage - Discharging X4 X2 Connectors X1 X2 X3 X4 Z002 connectors / signals DC + DC + DC DC - 18 Secondary rectifier card Z003 Operating diagram X5 X6 X7 X8 Z003 X1 X2 X3 X4 X5-X8 X1-X4 - Rectifying - Snubber - Protection against HF Connectors X1 X2 X3 X4 X5 X6 X7 X8 Z003 connectors / signals Main transformer Main transformer Main transformer Main transformer Secondary choke Secondary choke Secondary choke Secondary choke Operational mesurings C X5 X6 X003, machine (-) pole X7 X8 Z003 X1 C. Voltage after secondary rectifier card Z003, set values 50 A/16,5 V X2 X3 X4 19 Control card A001 X5 X6 X7 X9 H7 X2 F1 X17 F2 H8 H4 X15 X14 X13 X16 X4 H2 H10 X1 H9 H1 X11 X3 X8 X10 Operating diagram - Microcontroller - PWM circuit - Secondary voltage measurement - Secondary current measurement - IGBT driver - Auxiliary device connection - Auxiliary power supply - Machine size jumpers (J1, J2) - Primary current limit jumpers (J3, J4, J5) - Operational jumpers - LED’s - Water cooler connection 20 Control card A001 Connectors X1 A001 / X1 DC-link voltage (+) X2/1 X2/2 X2/3 A001 / X2 20V auxiliary voltage~ 20V auxiliary voltage ground 20V auxiliary voltage~ X3/1 X3/3 X3/4 X3/6 IGBT emitter IGBT emitter IGBT gate IGBT gate X4/1 X4/3 X4/4 X4/6 IGBT emitter IGBT emitter IGBT gate IGBT gate X5/1 X5/2 A001 / X5 Fan (-) (M002) Fan (+) (M002) X6/1 X6/2 X7 X8/1 X8/3 X8/4 X8/5 X8/6 X8/7 X8/9 X8/10 X8/11 X8/12 A001 / X3 A001 / X4 A001 / X6 Fan (-) (M001) Fan (+) (M001) A001 / X7 Production programming bus A001 / X8 Current transformer ~ Primary current limit jumper (J3) Primary current limit jumper (J4) Primary current limit jumper (J5) GND Current transformer ~ GND (Primary current limit jumper J3) GND (Primary current limit jumper J4) GND (Primary current limit jumper J5) GND X9/1 X9/2 X9/3 X9/4 X9/6 X9/7 X9/8 X9/9 X9/10 X9/11 A001 / X9 / KM System bus DATA System bus DATA B GND + 50 V Connection A002 X1/4 - X9/1 X9/2 X9/3 X9/4 X9/6 X9/7 X9/8 X9/9 X9/10 X9/11 A001 / X9 / KMS System bus DATA B System bus DATA B +50V +50V +5V +5V Analog DATA Analog DATA GND GND X10/1 X10/2 X10/3 X10/4 X10/5 X10/6 X10/7 X10/8 X10/9 X10/10 X10/11 X10/12 A001 / X10 Shunt (+) Secondary voltage (+) Machine size jumper J1 Machine size jumper J2 Shunt (-) TxD0 (possible future use) RxD0 (possible future use) GND GND(Machine size jumper J1) GND(Machine size jumper J2) J6 J7 J8 J9 (X005) (X006) (X005) (X006) (X005) (X006) (X005) (X006) (X006) (X005) A001 / X11 Not connected Forced programming mode For future purposes For future purposes For future purposes 21 Control card A001 Connectors A001 / X13 X13/1 PTC, Rg 101 (Z001) X13/2 PTC, Rg 101 (Z001) A001 / X14 X14/1 PTC, Rt 101 (T001) X14/2 PTC, Rt 101 (T001) A001 / X15 X15/1 PTC, Rg 201 (Z003) X15/2 PTC, Rg 201 (Z003) X16/7 X16/8 X16/9 X16/10 A001 / X16 H002 + (yellow led) H002 H001 + (green led) H001 - X17/1 X17/2 X17/3 X17/4 X17/5 X17/6 A001 / X17 +24V CLU_fault GND CLU_AD_CH1 CLU_AD_CH2 ON/OFF Operation of the LEDs on control card H1 H2 H3 H4 H5 H6 H7 H8 H9 H10 A001 / LEDS IGBT gate pulses IGBT gate pulses IGBT gate pulses IGBT gate pulses +15V +5V Remote control unit connected Data communication Micro controller operation Micro controller operation H1-H4: Indicate the existence of the gate pulses. H5, H6: Indicate that auxiliary voltages exist (+5V and +15V). If these Leds are not lit when the power source is switched on, first thing to do is check if control card fuses are OK. H7, H8: Indicate operation of the auxliary device connection. LED H8 indicates that there is data communication taking place through the system bus when it is lit. LED H7 indicates that remote control unit is connected when it is lit. H9, H10: Indicate state of the microcontroller. In normal situation both leds should be lit. 22 Motor control card A002 X4 X3 X1 X2 Operating diagram - WF-motor control - Connection to the panel card P001 - Remote controller connection - MIG gun connection - Solenoid valve connection - Fuse - ID-Chip connection (MSF) 23 Motor control card A002 (A001 = MSF) Connectors X1/1 X1/4 A002 / X1 / KM Connection to A001, X9/4 Connection to A001, X9/10 X1/1 X1/3 X1/4 X1/5 X1/6 A001 / X1 / MSF Bus +50V Tacho +5V Bus GND Tacho GND Tacho Signal X2 A002/A001 / X2 Connection to panel card X4/2 X4/3 X4/4 X4/6 X4/8 X4/11 X4/12 X4/14 X4/15 A002 / X4 / MF Start Motor+ U-measurement Pot +5V Connection A001 X9/2 WF-pot Valve GND Motor - X4/1 X4/2 X4/3 X4/4 X4/5 X4/6 X4/7 X4/8 X4/9 X4/10 X4/11 X4/12 X4/13 X4/14 X4/15 A001 / X4 / MSF Pot GND Start 2 Motor + Pot 2 Start 1 Pot +5V ID Bus 2 Bus Data General I/O Valve Pot 1 Valve + ID Bus 1 GND Motor - 24 ID chip card A002 (MSF) A002 ID-chip card Connectors TP1 TP2 A002 ID Bus 1 (connection to A001) ID Bus 2 (connection to A001) 25 Panel card P001 / KM Operating diagram - Main micro controller - User interface (buttons, potentiometers, displays, LED’s) - Connection to the A002 Connectors X2 P001 / X2 Connection to A002 26 Error codes Power source MIG Logic Curve Access Robot Interface MIG / TIG Unit User interface Others Err 2: Err 3: Err 4: Err 5: Err 11: Err 12: Err 13: Err 14: Err 15: Err 21: Err 22: Err 23: Err 31: Err 54: Err 55: Err 61: Err 153: Err 154: Err 155: Err 161: Err 162: Err 171: Err 172: Err 173: Err 184: Err 185: Err 201: Err 221: Err 222: Err 223: Err 224: Err 225: Err 241: Err 251: Err 252: Err 254: Err 255: Err 999: 1 ..... 50 51 ….. 100 101 ….. 130 131 ….. 150 151 ….. 200 201 ….. 250 0 ….. 999 Power source undervoltage ( new start up ) Power source overvoltage ( new start up ) Power source is overheated Water unit alarm Two units have the same address in the system bus Data error on communication (2) Member of a wrong FastMIG family connected Data communication problem between power source and auxiliary unit Power source program / updating method problem Power source´s control card +5 V aux. Voltage too low Power source´s control card +15 V aux. Voltage too low Temporarily power source overvoltage Power source calibration error. Welding only possible with default values. No data communication from power source. Perhaps faulty cable/connector. Welding forbidden (congiguration / system bus reserved) The water unit is not found. Cooling unit may be OFF. Overheating of liquid-cooled gun Wire feed motor overcurrent. Perhaps the wire liner is blocked or gun cable too curvy. Wire feed motor overload. Motor´s current is too close to the limit. Warning of the wire feed unit overheating Overloading of the wire feed motor Configuration of the equipment can not be found. Gun start wires cross-connected. Wrong configuration code has been supplied Operation is not activated with right configuration code Control cable not connected or faulty. Machine program update error. Wrong program or updating method. Usage of PMT-gun prevented Data error of the panel (1) Data error of the panel (2) Data error of the panel (3) Data error of the panel (4) Program updating problem. EEPROM is faulty DLI data communication error(another unit in the bus is using same code=conflict) DLI data error (2) DLI data communication error(connection to other units has been interrupted(maybe bad connectors or cable damages) DLI data communication error(program update problem, maybe a wrong program version etc) Unidentified error (systembus has sent an error message not identified by the panel) 27 Setup menu MF 29 / 33 FastMig Basic (MF) SETUP menu SF 51, 52, 53, 54 Normal MIG 1-MIG FR-MIG All MIG processes MMA FastMig Synergic (MSF) setup menu 28 Wire feed speed calibration / KM • In factory set Wfs is adjusted in the range of 4...100 without any unit • LED light and feed roll symbol tells that the parameter to be set is Wfs • After Wfs Calibration m/min unit is displayed • Drive filler wire through the MIG gun and contact tip • Enter to User Setup Menu by pressing SETUP button ( appr 5 s ) • Select the Calibration menu ( CAL ) with left side potentiometer • Select "Enter" ( Ent ) with right side potentiometer • Approve your selection by pressing briefly REMOTE / LOCAL key • Select 'm/min' as calibration value of the quantity with right side potentiometer • Approve selection by pressing briefly REMOTE / LOCAL key • Set first Calibration point (e.g. 2.0 m/min ) with left side potentiometer 1. Press MIG gun trigger and let the wire run until it stops automatically 2. Measure the length of feeded wire with the accuracy of 1 cm 3. Enter wire length to the panel display ( cm ) with right side potentiometer 4. Approve your selection by pressing briefly REMOTE / LOCAL button • Set second Calibration point (e.g. 18.0 m/min ) • Repeat steps 1 - 4 with left side potentiometer • Message "Suc cES" in the display inform that calibration has ended successfully • After Calibration panel returns to the operation mode 29 Wire feed speed calibration If wire feeding speed is not correct (too slow or too fast), motor control card A002 must be calibrated by following instruction: • Set ‘MIN’ and ‘MAX’ -trimmers to middle position. • Set ‘IR-comp’ -trimmer to clock vice maximum. • Set wire feeding speed to maximum from the panel (Basic: 100, Synergic: 25,0 m/min). Adjust ‘MAX’ –trimmer until wire feeding speed is same than value adjusted from the panel. • Set wire feeding speed to minimum from the panel (Basic: 4, Synergic: 1,0 m/min). Adjust ‘MIN’ –trimmer until wire feeding speed is same than value adjusted from the panel. • Check/adjust minimum and maximum again until both are OK. • If adjustment range is too small, decrease IR -compensation and adjust minimum and maximum again. R87 max. IR comp R24 min 30 Structure KM / KMS Mains connector and varistors Z001 Main circuit board Z002 DC-link Capasitor board S001 Main switch R001 Shunt resistor P001 Panel card A001 Control card A002 (KM) Wire feed control card Water cooler Power connector 31 Structure KM / KMS T002 Auxiliary transformer L002 Secondary choke Capacitors and varistors L001 Choke Z003 Secondary rectifier diodes 32 Structure MF 29 / 33 Dura Torque wire feeding mechanism Control cable connector & wiring Axle for wire reel coop Welding gun connection Solenoid valve Welding current connector & copper bar Dura Torque wire feeding mechanism 33 Structure MSF 53 / 55 / 57 A001 Motor control card A002 ID-chip card 34 IGBT testing E2 C1 C1/3 X15 X14/G3 B1/4 X14 G3 X12 G1 X15 E3 X13 E1 B2/6 X11/ X10/G4 X13 X12/G1 X9 X8/G2 X6 C2E1/1 X6 X7 X10 G4 X7 X8 G2 X11 E4 X9 E2 E2/2 C1/3 B1/4 X14 G3 G X12 C E G1 X15 E3 X13 E1 B2/6 B2/6 E2/2 C2E1/1 X7 X10 G4 C2E1/1 X6 C1/3 B1/4 X8 G2 TR 2 IGBT-TESTER TR 1 ON CONTROL OFF X11 E4 X9 E2 E2/2 35 IGBT replacing Mounting the IGBT to the heat sink The tools and premises used in this work must be clean and free of dirt and dust. Even very small particles (0,050mm) between the surfaces may increase the gap between heatsink and module, causing overheating ans possible damage. Heat transfer compound is to be spread in even layer of approximately 0,1 mm onto the module base. Then the module should be immediately mounted on the heatsink, in order to minimize the possibility of dirt getting between the components. Firts, all the M5 type screws are tightened 0,5...2 NM. After a few minutes the module can be tightened into the torque of 3 NM. 36