Kemppi Master 1400 Service Manual - General

Summary of Master 1400

  • Page 1

    Service manual ver. 1.0 1400 1500 2200 2800 3500 1500 2200 2800 3500

  • Page 2: Contents

    Contents general 3 technical data, switches and connectors 3-6 mastertig function panels 7-10 operating principle 11 igbt gate pulse (2800/3500) 12 voltage over the lower igbt (2800/3500) 13 voltage after the secondary diodes (2800/3500) 14 igbtgate pulse (1400-2200) 15 voltage over the lower igbt (...

  • Page 3: General

    Master- and mastertig-power sources are mma and tig power sources designed for demanding professional use. Master- and mastertig-power sources are igbt-inverters, controlled by pwm-principle. Operation frequency is approx. 18 khz. 5 power source sizes are available; 1~ 140 a, 1~ 150 a, 3~ 220 a, 3~ ...

  • Page 4

    Master 1500 1 2 3 4 5 1 main switch s001, welding current connectors and dynamics adjustment 2 overheat protection signal lamp 3 remote controller connection 4 local / remote control 5 current adjustment potentiometer supply voltage 1 ∼,50/60 hz connection power 20% ed 60% ed 100% ed supply cable/ f...

  • Page 5

    Master 2200 1 main switch s001, welding current connections and dynamics adjustment 2 i/0-signal lamp 3 remote controller connecyor 4 overheat protection signal lamp 5 remote / local control selection 6 current adjustment potentiometer 1 2 3 4 6 5 supply voltage 3 ∼,50/60 hz connection power 25% ed ...

  • Page 6

    Master 2800 and 3500 1 main switch s001 and welding current connectors 2 i/0-signal lamp 3 overheat protection signal lamp 4 dynamics adjustment 5 current adjustment potentiometer 6 local / remote control 7 remote controller connector 1 2 3 4 6 5 7 supply voltage 3 ∼,50/60 hz connection power 35% ed...

  • Page 7

    Mastertig 1500 and 2200 1 main switch s001, dynamics adjustment and welding current connections 2 current adjustment potentiometer 3 overheat protection signal lamp 4 local / remote control selection 5 remote controller connector 1 2 3 4 5 pregas time pause current postgas time 2t/4t-selection ignit...

  • Page 8

    Minilog-panel pause current post gas time 2t/4t-selection ignition method and process selection downslope time pulse frequency minilog-operation selection, minilog-current adjustment minilog-functions not in use current upslope time, continous welding continous welding selection pulse welding select...

  • Page 9

    Mastertig 2800 and 3500 1 2 3 4 6 1 main switch s001 and welding current connectors 2 i/0-signal lamp 3 overheat protection signal lamp 4 dynamics adjustment 5 current adjustment potentiometer 6 local / remote control selection 7 remote controller connector 5 7 pregas time pause current postgas time...

  • Page 10

    Minilog-panel pause current postgas time 2t/4t-selection ignition method and process selection downslope pulse frequency minilog-function selection, minilog current adjustment minilog-functions not in use current upslope time adj. Continous welding continous welding selection pulse welding selection...

  • Page 11: Operation Principle

    Operation principle the power stage in master- and mastertig- power sources is a traditional half-bridge, where the intermediate circuit´s dc-voltage is halved by load capacitors c2 and c3. Igbt-transistors are used as power switches. When both igbts are not conductive, no power is transferred. When...

  • Page 12

    Igbt gate pulse with minimum power (2800/3500). Inverter operating frequency approx. 19 khz (measuring point a). Igbt gate pulse with maximum power (2800/3500). Inverter operating frequency approx. 19 khz (measuring point a). A igbt gate pulse (master / mastertig 2800/3500) a a 12.

  • Page 13

    B voltage over the lower igbt with minimum power (2800/3500). Inverter operating frequency approx. 19 khz (measuring point b). Voltage over the lower igbt with maximum power (2800/3500). Inverter operating frequency approx. 19 khz (measuring point b). Voltage over the lower igbt (master / mastertig ...

  • Page 14

    C voltage over the secondary diodes with minimum power(2800/3500). Frequency is approx. 38 khz (measuring point c). Voltage over the secondary diodes with maximum power (2800/3500). Frequency approx. 38 khz (measuring point c). Voltage after the secondary diodes (master / mastertig 2800/3500) c c 14.

  • Page 15

    D igbt gate pulse (master / mastertig 1400/1500/2200) igbt gate pulse with minimum power (1400/1500/2200). Inverter operating frequency approx. 18 khz (measuring point d). Igbt gate pulse with maximum power (1400/1500/2200). Note. Inverter operating frequency approx. 25 khz (measuring point d). D d ...

  • Page 16

    E lower igbt control (gate pulse; measuring point d / voltage over the lower igbt; measuring point e). Voltage over the lower igbt (master / mastertig 1400/1500/2200) e master 1400/1500 master 2200 d d e d 16.

  • Page 17

    Voltage after the secondary diodes (measuring point f) and lower igbt gate pulse (measuring point d). F voltage after the secondary diodes (master / mastertig 1400/1500/2200) f master 1400/1500 master 2200 d d f d 17.

  • Page 18: Troubleshooting

    Troubleshooting 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. Also check the condition of the welding cables, welding guns / torches and all consumable parts....

  • Page 19

    Disturbance possible cause remedy the power source will not deliver full power a net fuse has blown faulty supply cable faulty main switch faulty primary side power semi- conductor faulty control card a001 faulty main circuit card faulty secondary unit faulty main transformer faulty control card a00...

  • Page 20

    Disturbance possible cause remedy tig-process logic functions are not working correctly faulty adjustment potentiometer faulty flat cable between control cards a002 and a003 faulty control card a002 check the adjustment potentiometers check the flat cable (see page 23) replace control card a002 (see...

  • Page 21

    Gate buffers controller and pwm development set value circuit mma ignition locking mma dynamics ocv adjustment av~40 fan control overheat protection power supply control to igbt net voltage watch actual current value current information to tig i2 u2 tig/mma current instruction control card a001 bloc...

  • Page 22

    The tig-section provides these programmatic functions: • pre- and postgas timings • up- and downslopes • tacking automatics • switch functions (2t/4t) • pulse functions • pulse led control • ignition spark control and watch • contact ignition control and watch • power source start and set value mast...

  • Page 23

    Signals between control cards a001 and a002 (mastertig 1500-3500) signals between control cards a002 and a004 (mastertig 2800-3500) 5/1 26 vac 5/2 spark generator on/off 5/3 start switch detection x6/3 (a004) gnd 1 current set value from power source (0,5…5 vdc) 2 current set value to power source (...

  • Page 24

    X2 x3 x1 x10 x11 r70 x17 x16 x15 x18 r48 r47 r98 r49 x8 x4 r47 maximum current r48 mma ignition current r49 minimum current r70 inverter frequency r98 set value min. (tig) clo sed x15 mma op en x15 scratch-tig x16 x17 x18 ocv approx. + 80 v x18 ocv approx.. + 40 v control card a001 layout (master / ...

  • Page 25

    Control card a001 layout (master / mastertig 2800/3500) r33 maximum current r53 mma ignition current r72 minimum current r75 inverter frequency r93 set value min. (tig) clo sed x18 mma op en x18 scratch-tig x15 net voltage 3 ∼ 400 v x15 net voltage 3 ∼ 460 v x16 net voltage 3 ∼ 460 v x16 net voltage...

  • Page 26

    Control card a002 layout (master / mastertig 1500/2200) x1 x1 0 x11 x2 x7 x4 x3 f1 0,63 a t r43 x20 x 21 x2 2 x1 2… …… …. X1 9 jumpers when a jumper is disconnected: x12 tacking automatics goes off x13 downslope time becomes non-linear, downslope times become longer with low currents x14 postgas bec...

  • Page 27

    Control card a004 layout (master / mastertig 2800/3500) x6 x5 x1 x4 f1 1,6at r13 r1 r1 power (spark) r13 voltage (spark) igbt gate pulses control card a001 functional testing control card power supply ? (2 x 13 vac) temperature watch ptc ? Set value information ? X2 x3 x1 x1 2 x1 3 x1 0 x1 1 r70 x1 ...

  • Page 28

    Control card a002 functional testing 1 current set value to power source (0,5…5 vdc) 2 current set value to power source (0,5…5 vdc) 3 gnd 4 gnd 5 gnd 6 gnd 7 8 output voltage from power source (ocv on mma 75 vdc) 9 10 11 12 13 mma/tig-selection (tig = 4,5 vdc, mma = 0 v) 14 26 vac from power source...

  • Page 29

    A=pin 2 voltage pulse ratio approx. 10 %, pause current 40 % and cycle time 1,5 s (0,7 hz) b= pin 1 voltage set value information from control card a001´s set value circuit a= pin 2 voltage pulse ratio approx. 50 %, pause current 40 % and cycle time approx. 0,2 s (50hz) b= pin 1 voltage set value in...

  • Page 30

    Control card a004 functional testing (mastertig 2800/3500) 5/1 24 vac 5/2 spark generator on/off 5/3 start switch detection x6/3 (a004) gnd mastertig 2800/3500 control card a004 generates the ignition spark for tig and it also reads the torchswitch states. The torch switch is separated from other el...

  • Page 31: Notes

    31 notes.