DTR do KM400 KMS400
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