TECHNICAL SERVICE MANUAL FOR KEMPOWELD
TROUBLESHOOTING CHART
TROUBLE CAUSE REMEDY
Welding stops occasionally or some
other occasional disturbances.
Faulty intermediate cable or
connector.
Faulty switch in mig gun.
Loose start wire(s) in mig gun.
Check/repair the cable. See TABLE
FOR CONTROL LINES, table 1.
Check and change the switch if
needed.
Check and tighten the start wire(s)
inside the gun.
Machine is overheating because the
fan don´t start.
Faulty fan or PCB A001 . Check the 24 VDC voltage from fan
connector X2/12 and X2/13, if it is all
right change the fan, if it is not
change the PCB.
See, TROOUBLE SHOOTING FOR
PCBs appendix 1.
Wire feeding speed set value can´t
adjusted.
The set value potentiometer RW102
is faulty.
Check and change the 10KΩ
set value potentiometer RW102 if
needed.
KMW-sync is not working. Faulty connection in connector X1. Check and repair connection
according to PICTURE 1.
If some other push-pull gun than
Binzel or Hulftegger is in use the gun
is pulling to fast.
Wrong motor voltage. Select correct jumper combination
(there are two jumpers X1 and X2
and the fine adjustment for voltage
can made from MP-SYNC PCB)
from MP-SYNC control card. See
also PICTURE 2.
MSD-1 meter unit don´t work. Ribbon cable between MSD-1 and
control card A001 is loose or cut.
Faulty MSD-1 unit.
Check and tighten the cable, check
also the control voltage for MSD-1
from A001 X3/16 and X3/1 the value
should be 12 V.
Check as mentioned above if it´s all
right, chage the MSD-1.
Occasional disturbances with KMW-
timer unit.
Ribbon cable between KMW-timer
and control card A001 is loose or
cut.
Faulty KMW-timer unit.
Check and tighten the ribbon cable.
Check and change the KMW-timer
unit. See also potentiometers from
PICTURE 3.
The water circulation stops after 5 s
of welding.
Low cooling water volume.
Air bubbles or leakages in cooling
system.
Faulty pressure switch
Check the water and fill it if needed.
Follow the instructions of
Kempoweld Operation Instructions/
Operation Disturbances.
Check/change the pressure switch.
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