SERVICE MANUAL

MVU 20
IN FASTMIG M & X

Kemppi Oy
CONTENTS

1. READ THIS FIRST ........................................................................................................................................... 1

2. GENERAL......................................................................................................................................................... 2
3. TECHNICAL INFORMATION ........................................................................................................................... 2
3.1. Technical data ........................................................................................................................................... 2
3.2. Wiring diagram .......................................................................................................................................... 3
3.3. Description of operation ............................................................................................................................ 4
3.3.1. A002 Control card .............................................................................................................................. 4
3.3.2. A003 and A004 Capacitor card .......................................................................................................... 5
4. SERVICE INSTRUCTIONS .............................................................................................................................. 6
4.1. Machine assembly .................................................................................................................................... 6
4.2. Low voltage testing ................................................................................................................................... 6
4.3. Measurements........................................................................................................................................... 7
5. NOTES ............................................................................................................................................................. 8

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Service manual MVU 20 Version 1.0 16.7.2014

1. READ THIS FIRST

220-230 VAC or 380-440 VAC 50/60Hz and 560 VDC or higher voltages exists inside the unit.

Before removing any covers or commencing any testing or measurement disconnect the power source from the
main supply voltage.

Dangerous DC voltage still exists few minutes after the removal of the main supply voltage.

Wait at least one minute for the capacitors to become discharged before making any maintenance.

The device may be repaired only by a person legally authorized to perform electric work.

This model requires a safety test after repair work to ensure safety for the user. Correct procedure is described
in the safety test, repair work and testing manual. For PE test in insulation resistance testing, use the gas con-
nector as chassis connection.

Measured values may differ from the type and model of multimeter used.

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Service manual MVU 20 Version 1.0 16.7.2014

2. GENERAL

This MVU 20 unit is used with Fastmig M 420MV and X 350MV models in 3-phase 230 or 400 VAC mains.
Design has been changed from previous MVU 10 model which was used with KM 400 MVU and KMS 400 MVU
models. Main difference is that rectifier units have been changed to module versions and capacitors have been
spread over the PCB to improve those cooling.

Unit has the following electrical components:

- A002 Control / capacitor card
- A003 and A004 Capacitor cards
- T002 Auxiliary transformer
- T003 Auxiliary transformer
- T004 Auxiliary transformer
- G003 Rectifier
- M003 Fan
- K001 Contactor
- Extension for water cooler from power source

3. TECHNICAL INFORMATION

3.1. Technical data

For all technical data, refer to Fastmig M 420MV and X 350MV specifications.

230 V range 400 V range

Connection voltage 3~50/60 Hz 220 V -10% …230V + 380 V -10% …440 V +

10% 10%

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Service manual MVU 20 Version 1.0 16.7.2014

3.2. Wiring diagram

Check the latest versions of main wiring diagrams for Fastmig M 420MV and X 350MV from the Kemppi
Channel. These can be found under Service & Spare parts -> Main circuit drawings.

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Service manual MVU 20 Version 1.0 16.7.2014

3.3. Description of operation

MVU 20 unit detects the mains voltage range and according to this voltage, additional capacitors will be taken in
use in 220 – 230 VAC mains. Main voltage detection logic exists in A002 control / capacitor card. This control
card also controls the K001 contactor which is used in 220 – 230 VAC mains. In case of 220 – 230 VAC mains
DC-link capacitors and rectifiers together acts as a voltage doubler and so on the DC-link voltage is high
enough to enable a normal performance in power source. DC link voltage is created in MVU 20. Auxiliary volt-
ages are created in MVU 20 for main power source also. A fan of MVU 20 unit is controlled as in parallel with
main power source.

3.3.1. A002 Control card

DC-link capacitors Rectifier

A002 Control card
 Phase detection for all phases.
 Detection of mains voltage for 3-phase 230 V or 400 V range.
When lower voltage is detected, a voltage doubler will be taken in to use.
 DC link voltage is rectified in MVU 20 unit for main power source.
 Auxiliary voltages for control card A002 are created with T003 and T004 auxiliary transformers.
 Auxiliary voltages for power source is created with T002 auxiliary transformer in MVU 20.

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Service manual MVU 20 Version 1.0 16.7.2014

3.3.2. A003 and A004 Capacitor card

DC-link capacitors Rectifier

A003 and A004 Capacitor cards
 Additional rectifier and DC link capacitors for 230 V range.
 Connected to A002 card with copper rails.
 A002 card handles the connection to main power source.

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Service manual MVU 20 Version 1.0 16.7.2014

4. SERVICE INSTRUCTIONS

4.1. Machine assembly

2.
1.
4.
3.

8.

5.
6.
7.

Layout

1. K001 Contactor
2. T003 Auxiliary transformer
3. A002 Control card
4. M001 Fan
5. A003 and A004 Capacitor cards
6. T004 Auxiliary transformer
7. G003 Rectifier
8. T002 Auxiliary transformer

4.2. Low voltage testing

This unit can be tested while low voltage testing while connected to main power source, M or X model.
Instructions for this sequence can be found in service manual of those models with one exception,
T002 auxiliary transformer connection to primary is in MVU 20 unit, not in the power source as in normal mod-
els.
Easiest way to test control side is to disconnect X2 connector from A001 control card from power source and
feed 22 VAC to points 1-2 or 2-3. Second phase is to connect X2 connector and feed throught it the 22 VAC to
control side and T002 secondary to see DC link voltage and once main switch is on, also mains from cable.
NOTE !!! Remember that welding won’t be possible due to limitations of Kemppi Multipower and MVU 20 unit
can be tested only in 400 V range.

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Service manual MVU 20 Version 1.0 16.7.2014

4.3. Measurements

V1 Rectifier
X5

X4 X1
G003 Rectifier
DC + AC

X3

AC DC --
DC-link capacitors

V2 Rectifier X2

NOTE !!!
Internal layout of PCB differs for
A002 and A003/A004 cards but
rectifier measurement is the same.
Diode Value
Forward 0,4- 0,52V
Reverse Infinite

Measuring points:
X4 -> X5
X5 -> X2
X5 -> X1
X2 -> X3
X1 -> X3
OR short version:
X4 -> X5
X5 -> X3

Values may differ due to multime-

ter and diodes can’t be measured
individually without desoldering
the module.
Some values may be double as
attached diagram shows.

A002, A003, A004 measurements

Rest of the measurements for operating voltages can be made according to main circuit drawing.

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Service manual MVU 20 Version 1.0 16.7.2014

5. NOTES

For full information of servicing the power source, check appropriate separate service manual for power source.

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