Service manualVer. 1.1

Contents

Technical data…………………………………………… 3Switches and connectors……....…………………………4Operation principle….…………………………………...5Main circuit……………………………………………….6Main circuit diagrams…………………………...……….7Troubleshooting diagram………………………………...8Main circuit card Z001

Functions / connectors…………………………. 9Layout……………………...…………………... 9, 10Main transformer T001 primary voltage……….10, 11

Secondary diode card Z002Functions / connectors…………………………..12Layout………………………………………….. 12, 13Voltage after secondary diode card Z002…….... 13, 14

Control card A001Functions / connectors….……………………….15Layout………………………………………….. 16IGBT gate pulses………...……………………...16, 17Wire feed on / off control……............………….18Inverter on / off control………….........………...18Secondary voltage set value……...……………...19Overheat protection……….……………………..19

Control card A002Functions / connectors…….…………………….20Layout………………………………………….. 20Wire feed on / off control……............………….21Wf-speed set value……….............................….. 21Wire feed motor M001 voltage..............………..22Wf-speed minimum and maximum adjustments..22

Structure…………...…………………………………….. 23, 24IGBT testing and replacing……….......…………………25, 26Notes……………………………………………................ 27

2

Technical data

Supply voltage 3∼ 400 V ±15% , 50/60 Hz

Loadability(Connection power)

40% ED 250 A / 26,5 V (12 kVA)60% ED 207 A / 24 V (10 kVA)100% ED 160 A / 22 V (7,5 kVA)

Supply cable (fuse) 4 x 1,5 mm 2,5 m (16 A slow)Welding voltage adjustment range 10 - 30 V

Wire feed speed adj. range 1 - 18 m/minPower factor 0,64Efficiency 0,87

Filler wireFe, SsFlux core wireAlCuSi

0,6…1,0 mm0,9…1,2 mm0,9…1,2 mm0,8…1,0 mm

Wire spool diameter (weight) 2520: 200 mm (5 kg)2530: 300 mm (15 kg)

Dimensions (weight) 2520: L440 x W240 x H320 (17,5 kg)2530: L525 x W270 x H320 (20 kg)

OCV 40…50 V

3

Switches and connectors

1 Wf-motor

2 Pressure adjustment screw

3 Pressure lever

4 Wire guide

5 Feed roll

6 EURO-connector

Plus ( + )

Minus ( - )Return current connector

Euro-connector

1

2 3 4

56

1 2T / 4T selection

2 On-sign

3 Temperature protection sign (undervoltage)

4 Welding voltage adjustment

5 Wf-speed setting

6 Dynamics adjustment

4

Operation principle

KempactTM MIG 2520 and 2530 are compact MIG-inverter power sources designed for repairand installation work and for light or middle-weight industrial use.

KempactTM MIG 2520 and 2530 power sources are based on IGBT-technology and controlledby PWM-principle. Inverter operating frequency is 30 kHz.

All functions and welding properties of KempactTM Pulse-power sources are programmaticallygenerated.

KempactTM Pulse-power source´s power stage operating principle is shown below:

UG1

UG2

UG3

UG4

UT1

UG5

UL1

G1

G3

G2

G4

G5

L1UG1

UG3 UG4

UG2

UT1

UG5 UL1

approx. + 570 V

T1

5

KempactTM MIG-power source´s power stage is a full-bridge and an IGBT-module is used as apower switch.

When IGBT-transistors G1 and G4 conduct, there is positive voltage UT1 in main transformer T1primary and when IGBT-transistors G2 and G3 conduct there is negative voltage UT1 in maintransformer primary. Power is adjusted by changing the IGBT timings (PWM).

Main transformer T1 secondary voltages are rectified with a full-wave rectifier G5 and secondaryvoltage waves are dampened by secondary choke L1.

+ t

L2

X27

X24

X30

+ t

X11

X10 X9

X18

C8

C10

C13

C9

C11

C12

5

6

7

1 2

3 4V2

C6 C7

R13

X19 X20

L1

C4

C3

R12

R11

C2

C1

R10

R9

X2G3

X8G1

X3G4

X6G2

X1E3X7E1X21

X22

X4E4X5E2

V1

X23

R5

Main circuit

Primary circuit

Secondary circuit

U

C2 R6

V1

V2

V3

V4

V5R4

R3

V6

V7

V8

V9

V10C1 R5

X1

X2

X3 X4

R1

R2

X5

X6

X7

U

6

Main circuit diagram

7

General

Troubleshooting diagram

PROBLEM POSSIBLE CAUSE REMEDYThe power source doesn´t start. Net fuses or supply cable. Check the net fuses or supply cable

condition.

Power source overheat shieldyellow signal almp is on just afterstarting the machine up.

Net fuses or supply cable. Check the net fuses and supply cablecondition.

The power source can´t deliverfull power.

Net fuses or supply cable.

Main transformer T001 orsecondary diode card Z002.

Check the net fuses and supply cablecondition.

Check the main transformer T001ferrites and secondary diode carddiodes.

8

The machine may be repaired only by an authorized and licensed technician or workshop!

First do a visual check to find the possible loose connectors, broken wires or signs of overheating

Main circuit card Z001 functions / connectors

Main circuit card Z001 has the following operational blocks:•Overvoltage protection• EMI-filter• Primary rectifier• DC-link charging• DC-voltage filtering• Full-bridge IGBT-module

ConnectorsX1…X8 IGBT gates and emittersX9 Fan M002X10 ja X11 Aux. transformer T002X12, X14 ja X17 Net voltage 400 VacX13, X15 ja X16 Main switch S001X18 Protective earthX19 ja X20 Charging relayX21 ja X22 Main transformer T001X23 Intermediate circuit DC voltageX24, X27 ja 30 Main switch S001

Main circuit card Z001 layoutX1X2X3X4X5X6X7X8

X9X10X11

L1

L2L3

X18

X20X19

X30X24X27

X23

X22

X21

9

Main circuit card Z001 layout

Smoothing capacitors4 x 470 µF / 450 V

Full-bridge IGBT4 x 50 A / 1200 V

Primary rectifier50 A / 1600 V Varistors

3 x 550 V

DC-link charging resistor and relay

Main switch

EMI-filter

Main transformer T001 primary voltage

Z001a

Main transformer T001 transformation ratio 1:14

10

Main transfomers T001 primary voltage

Main transformer T001 primary voltage with values 50 A/16,5 V, meas. point a.

a

Main transformer T001 primary voltage with values 250 A/26,5 V, meas. point a.

a

11

Secondary diode card Z002 functions / connectors

Secondary diode card Z002 includes these operational blocks:• Secondary rectifying• Machine size coding• Overvoltage protection• Dampening circuit

ConnectorsX1 and X2 Main transformer secondaryX3 and X4 Euro-connectorX5…X7 Machine size coding

Secondary diode card Z002 layoutX5X6X7

X2

X1 X3

X4

12

Fast diode 10 x 60 A / 400 V

Varistor 2 x 175 V

Voltage after the secondary diode card Z002

b

13

Secondary diode card Z002 layout

b

Voltage after the secondary diode card Z002 with values 50 A/16,5 V, meas. point b.

c

Voltage after the secondary diode card Z002 with values 250 A/26,5 V, meas. point b.

b

14

Voltage after the secondary diode card Z002

Control card A001 has the following operational blocks: • Aux. voltages developement / -monitoring• Power stage on / off -control• Power stage PWM-control• Primary current measuring • Dynamics• Ignition pulse• Post current• Wire feed• Solenoid valve control• Temperature protection• Net overvoltage watch• DC-link charging• Start detection (2T/4T)• 4T-reset

Control card A001 functions / connectors

ConnectorsX1/1, 2 Aux. transformer T002X2/1, 2 PTC (IGBT)X3/1, 2 Charging relayX4/1, 2 PTC (L002)X5 Protective earthX7/1 + 5 VX7/2 GNDX7/3 + 5 Vref1X7/4 Secondary voltage set valueX7/5 + 5 Vref2X7/6 Wire feed speed set valueX7/7 GNDX7/8 2T/4T-switchX7/9 Overheat signal lamp controlX7/10 Secondary voltage from secondary

choke L001X7/11 Dynamics set valueX7/12, 16 EmptyX8/1, 5 Solenoid valve Y001X8/2, 3 Wire inch switchX8/4, 6 Gun switch

ConnectorsX9/1 + 5 VX9/2 GNDX9/3 EmptyX9/4 + 15 VX9/5 Wire feed on / off controlX9/6 Wire feed speed set valueX9/7 Secondary voltage from chokeX9/8 + 5 Vref2X9/9 GNDX9/10, 11 Current transformerX9/12 Secondary voltageX10/1 E1, IGBTX10/2 EmptyX10/3 E2, IGBTX10/4 G1, IGBTX10/5 EmptyX10/6 G2, IGBTX11 Intermediate circuit DC voltageX12/1 E4, IGBTX12/2 EmptyX12/3 E3, IGBTX12/4 G4, IGBTX12/5 EmptyX12/6 G3, IGBT 15

Control card A001 layout

X9

X11

H6

X12 H4 H3 X10 H5 X5 X4 X3 X2 X1

H2

H1

X7

X8LEDs:H1 + 5VH2 + 15VH3…H6 Gate pulses

Z001

c

IGBT gate pulses

16

Gate pulse with values 250 A/26,5 V, meas. point c.

c

IGBT gate pulses

Gate pulse with values 50 A/16,5 V, meas. point c.

c

17

Wire feed starts

Wire feed is started by turning down the voltage on connector X9/5.

Wire feed on / off -control

Inverter on

Inverter starts, when PWM circuit (N1) Shutdown -pin (16) voltage is down.

Inverter on / off -control

18

Secondary voltage set value

Secondary voltage set value voltage on connector X7/4.

Min. approx. 1,20 V

Max. approx. 4,60 V

In overheat situation the connector X7/9 voltage rises up and the yellow overheat protectionsignal lamp lights up.

Overheat 4,5 V

Overheat protection

19

Control card A002 functions / connectors

Control card A002 has the these operational blocks:• Wire feed motor control (PWM)• Power supply filtering• Overvoltage protection

ConnectorsX1/1 + 15 VX1/2 Wire feed motor plusX1/3 Output voltageX1/4 + 5 Vref2X1/5 Wire feed speed set valueX1/6 EmptyX1/7 GNDX1/8 EmptyX1/9 EmptyX1/10 Wire feed on / off -controlX1/11 Wire feed motor minusX1/12 GND

Control card A002 layout

X1

R32 (Min) R21 (Max)

F1 (6,3 AT)

20

Wire feed on / off -control

Wire feeding is started by turning down the voltage on connector X1/10.

Wire feed on

Wire feed speed set value voltage on connector X1/5.

Wire feed min. approx. 5,0 V

Wire feed max. approx. 1,0 V

Wire feed speed set value

21

Wire feed motor M001 voltage

a) b) c)

a) Wire feed motor M001 voltage 1 m/min setting, X1/2-X1/11b) Wire feed motor M001 voltage 10 m/min setting, X1/2-X1/11c) Wire feed motor M001 voltage 18 m/min setting, X1/2-X1/11

Wire feed speed minimum and maximum adjustments

After replacing control card A002 or wire feed motor M001 the wire feed speed must bechecked and if necessary, adjusted as follows:1. From panel set the wire feed speed to 18 m/min2. Check the actual wire feed speed and adjust it to 18…18,2 m/min, using trimmer R21.3. From panel set the wire feed speed to 2 m/min4. Check the actual wire feed speed and adjust it to 2…2,2 m/min, using trimmer R32.5. Re-check the speed adjustments and make sure the wire feed speed setting by the panel isoperating properly.

22

Structure

A001Control card

L002Secondary choke

Z002Secondary diode card

Z001Main circuit card

M002Fan

S001Main switch

A002Control card

Y001Solenoid valve

KempactTM MIG 2520

KempactTM MIG 2520

23

A001Control card

L002Secondary choke

Z002Secondary diode card

Z001Main circuit card

A002Control card

Y001Solenoid valve

M002Fan

S001Main switch

KempactTM MIG 2530

Structure

T001Main transformer

T003Current transformer

T002Aux. transformer

KempactTM MIG 2520 / 2530

24

IGBT testing and replacing

25

X2G3

X8G1

X3G4

X6G2

X1E3X7E1

X21

X22

X4E4X5E2

C1/3

C2E1/1

B1/4

X1

X2/G3X3/G4X4X5X6/G2X7X8/G1

X22

X21

C1

C1

E2

E2

B2/6

E2/2

X2G3

X8G1

X3G4

X6G2

X1E3X7E1

X21

X22

X4E4X5E2

C1/3

C2E1/1

B1/4

B2/6

E2/2

The IGBT module can be tested in two phases with an IGBT tester as seen in picture below:

26

IGBT testing and replacing

Mounting the IGBT to the heat sinkThe tools and premises used in this work must be clean, free of dirt and dust. Even very smallparticles (0,050mm) between the surfaces may increase the gap between heatsink and module,causing overheating and possible damage.

Heat transfer compound is to be spread in an even layer of approximately 0,1 mm onto themodule base. Then the module should be immediately mounted on the heat sink, in order tominimize the possibility of dirt getting between the components.

First all the M5 type screws are tightened to 0,5…2 Nm, after which the module can betightened into the nominal torque of 3 Nm. After a pause of some minutes the torques should bere-checked.

It is normal, that after the final tightening there is a slight collar of paste around the modulesides. This tells us, that the amount of paste is adequate.

27

Notes