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- MASTERTIG AC/DC 2000
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Kemppi MASTERTIG AC/DC 2000 Service Manual - Secondary Voltage U
Summary of MASTERTIG AC/DC 2000
Page 1
Service manual ver. 1.0
Page 2: Contents
Contents technical data…………………………………………… 4, 5 switches and connectors…....……………………………6-8 function panels…......…………………………………… 8, 9 jumper functions…...................................…...…………..10, 11 error codes………………………………………………. 12 operation principle………………………………………12-14 block diagram…………………………………...
Page 3: Contents
Contents mastertig 2000 ac/dc inverter controls……….............57-65 sec. Voltage u 2 using low-pass filter (2000)…..................65-69 mastertig 2500 ac/dc inverter controls……….............70-73 sec. Voltage u 2 using low-pass filter (2500)…................. 73-76 mastertig 3500 ac/dc inverter c...
Page 4: Technical Data
Technical data mastertig ac/dc 2000 supply voltage 1 - 50 / 60 hz 230 v +-10 % connection power tig max. 200 a / 6,8 kva 100 % 150 a / 4,5 kva mma max. 160 a / 7,3 kva 100 % 100 a / 4,2 kva w elding current range tig dc 3 a / 10 v … 200 a / 18 v ac 10 a / 10 v … 200 a / 18 v mma dc 10 a / 10 v … 160...
Page 5: Technical Data
Technical data mastertig ac/dc 2500 and 2500 w 3500 w supply voltage 3~50/60 hz 230,400,460v +/-10% 400 v + / - 10% loadability tig 70% ed 250 a / 7,5 kva 350 a / 11,7 kva tig 100% ed 200 a / 6,7 kva 320 a / 9,3 kva mma 40% ed 250 a / 10,3 kva mma 60% ed 350 a / 15,7 kva mma 100% ed 200 a / 7,9 kva ...
Page 6: Switches and Connectors
Switches and connectors shielding gas connection tig-torch connection welding current connection return current connection control cable connection, remote controller control cable connection, tig-torch supply cable main switch mastertig 2000 ac/dc shielding gas connection tig-torch connection weldi...
Page 7: Switches and Connectors
Switches and connectors shielding gas connection tig-torch connector welding current connection return current connector control cable connection, remote controller supply cable main switch mastertig 2500w ac/dc shielding gas connection tig-torch connector welding current connection return current c...
Page 8: Function Panels
Function panels pressure too low -signal lamp coolant overheating -signal lamp test switch torch cooling method selection switches and connectors 1 tig hf ignition /current selection 22 tig contact ignition/current selection 3 post gas time adjustment 0…100 s. 4 welding current downslope adj. 0…15 s...
Page 9: Function Panels
Function panels 1 tig hf ignition/ contact ignition selection 2 ac-tig frequency adjustment 50…200 hz 3 postgas time adjustment 0…100 s. 4 welding current downslope time adjustment 0…15 s. 5 current adjustment knob/selected parameter adj 6 local-/remote control selection/code lock 11 minilog-functio...
Page 10: Jumper Functions
The power source has extra functions and selections, that can´t be seen on the display normally. The jumper functions can sometimes solve special problems. The jumper function can be a simple on/off type function or it may have an adjustable value. Jumper functions in use: 1. Shut down the power sou...
Page 11: Jumper Functions
Jumper functions jumper on off j01 upslope upslope angle is constant, time is dependant on the set value. Upslope set time remains constant, not depending on the set value. J02 downslope downslope angle is constanttime is dependant on the set value. Downslope set time remains constant, not depending...
Page 12: Error Codes
Error codes err1 power source secondary voltage is > + 90 v for overi 4 seconds.I uin err net overvoltage operation principle mastertig ac/dc-power sources are designed for demanding professional use, suitable for tig- /mma welding, both ac and dc. Mastertig ac/dc-power sources are igbt-inverter pow...
Page 13: Operation Principle
Operation principle t001 r001 t003 v4 v6 tig v5 u g5 the main transformer t001 secondary voltages are rectified with a full wave rectifier v4 and the current type (dc+, dc- or ac) is chosen by igbts v5 and v6. Secondary circuit current is measured by shunt resistor r001. When the current type is dc+...
Page 14: Operation Principle
Operation principle t001 r001 t003 v4 v6 tig v5 u g5 when the chosen current type is ac, then the igbts v5 and v6 are conductive one at a time, with 50…200 hz frequency. Block diagram cooling unit control card a005 primary inverter control card a002 sec. Inverter control card a003 spark card a004 em...
Page 15: Filter Cards
Filter cards information of overvoltage to control cards a002 and a001 gnd + 15 v control to th e pr im ar y r ecti fier l1 l1 l2 l3 dc link + dc link - l3 + 15 v overvoltage watch gnd protection circuits against wrong supply voltage to primary rectifier mastertig 2000 ac/dc z001 mastertig 2500 ac/d...
Page 16: Filter Card Layout
Information of overvoltage to control cards a002 and a001 gnd + 15 v watch aux. Transformer t002 primary 400 vac to the primary rectifier l1, l2, l3 intermediate circuit dc l1, l2 mastertig 3500 ac/dc z002 the filter cards z001 (2000) and z002 (2500/3500) have overvoltage protection against low ener...
Page 17: Filter Card Layout
Filter card layout x3 x1 x15 x7 x5 x19 x24 x25 x22 x16 x13 x11 x9 r3 x23 x18 mastertig 2500 ac/dc z002 x6 x7 x1 x20 x4 x5 x19 x2 x15 x21 x9 x8 x11 x10 x13 x12 x18 x17 x16 x22 x14 mastertig 3500 ac/dc z002 17.
Page 18: Main Circuit Cards
Main circuit cards the primary rectifier vg102 rectifies the net voltage. The primary choke l001 and smoothing capacitors cz213…cz216 filter the dc voltage. Working capacitors cz201…cz212, main transformer t001 and igbt-transistor vg101 form the primary inverter. Primary circuit current is measured ...
Page 19: Main Circuit Cards
Main circuit cards the primary rectifier vg101 rectifies the net voltage. Primary choke l001 and smoothing capacitor c002 filter the dc voltage. The primary inverter´s working capacitors are mounted onto the main circuit card z001. Mastertig 3500 ac/dc z001 main circuit cards layout x4 x1 x6 x3 x2 x...
Page 20: Main Circuit Cards Layout
Main circuit cards layout x2 x1 x3 x5 x4 x9 x7 x6 x8 mastertig 2500 ac/dc z001 x8 x5 3/e1 x5 x5 x4 x9 x9 x10 x7 x7 mastertig 3500 ac/dc z001 20
Page 21: Voltage Selector Switch
Voltage selector switch voltage selector switch s003 is used to select the correct net voltage (3~ 230, 400, 460 vac). It sets the correct transformation ratios for the main transformer t001 and voltages for auxiliary transformer t002. Mastertig 2500 ac/dc s003 diode cards rectify the main transform...
Page 22: Secondary Circuit Components
Secondary circuit components the shunt resistor r001 is used to measure secondary circuit current. The spark transformer t003 increases the tig ignition spark to approx. 10 kv. C001 gives protection against the tig ignition spark. Reed-relay k001 protects the liquid cooled tig-torch, in case the coo...
Page 23: Diode Card Layout
Diode card layout the auxiliary transformer t005 generates the 230 vac supply voltage for the pump motor. The filter card z004´s ptc-resistors protect the auxiliary transformer t005, if a wrong supply voltage is selected by the voltage selector switch s003. Cooling unit mastertig 2500w ac/dc mastert...
Page 24: Filter Card Z004 Layout
Filter card z004 layout x5 x2 x1 x11 x12 x13 x4 x3 x6 pump motor control relay k1 power supply from control card a002 liquid-/gas cooling selection switch test switch to reed-relay k001 gnd cooling unit start control pressure watch s002 coolant temperature-ptc rw301 coolant overheat warning lamp too...
Page 25: Control Card A005 Layout
Control card a005 layout x1 k1 x2 control carda001 includes the following functional blocks: • processor • memories • displays • panel membrane switches read • potentiometers • net voltage watch • fan control • cooling unit control/watch • secondary igbt control • tig ignition spark control • soleno...
Page 26
Control card a001 connectors x1/1 machine size detection (1600/2500) x1/2 set value from the remote controller x1/3 process selecting from the remote controller x1/4 overheat protections (ptc) x1/5 machine size detection (2000) x1/6 fan control x1/7 net voltage watch from the aux. Transformer t002 s...
Page 27
Control card a002´s functional blocks: • pwm-development • primary igbt control • current and voltage adjustment loop • aux. Voltages development + 5, ± 15, + 16 and + 24 v • secondary overvoltage watch • primary current limiting circuit • net overvoltage and undervoltage watch • fan control power s...
Page 28
Control card a002 connectors x3/1-2 primary igbt control x4/1-2 primary igbt control x5 aux. Transformer t002 0v x6 aux. Transformer t002 13 vac x7 aux. Transformer t002 13 vac x8/1 tig ignition spark control x8/2 13 vac x8/3 tig-torch start detection x8/4 + 24 v x8/5 gnd x9/1-2 solenoid valve x9/3-...
Page 29: Control Card A002 Layout
Control card a002 layout x8 x1 x10 x2 x3 x4 x11 r118 max current dc- x9 r119 max current dc+ x14 r44 inverter frequency x20 x5 x6 x7 x22 3,15 at x8 x1 x10 x2 x3 x4 x11 r118 max current x9 x14 r44 inverter frequency x20 x5 x6 x7 x22 from serial number 985660/l onwards 29.
Page 30
Control card a003 functions / connectors control card a003´s functional blocks: • secondary igbt control power stage • remote controller connection • ac-tig aux. Pulse developement • ocv circuit x1/1 secondary igbt control x1/2 + 5 v x1/3 secondary igbt control x1/4 - 15 v x1/5 + 15 v x1/6 gnd x1/7 ...
Page 31: Control Card A003 Layout
Control card a003 layout l1 x12 x3 x5 x8 x7 h1 (dc-) h2 (dc+/ac) x1 x11 x4 x2 l1 x12 x3 x5 x8 x7 h1 (dc-) h2 (dc+/ac) x1 x11 x4 x2 from serial number 980039/l onwards 31.
Page 32: Control Card A004 Layout
Control card a004 includes these operational blocks: • tig ignition spark development • tig-torch start detection control card a004 functions / connectors x1/1,3 spark transformer primary (approx. 1 kv) x2/1,3 360 vac from aux. Transformer t002 x3/2 tig-torch start detection x3/3 13 vac x3/4 + 24 v ...
Page 33: Structure
Structure z001 s001 t002 a002 a003 vg102 t001 ga001 m001, m002 l1 a001 z002 a004 vg101 vg201, vg202 y001 t003 r001 mastertig 2000 ac/dc 33.
Page 34: Structure
Structure a002 a003 t002 z002 s001 vg201, vg202 ga001 vg101 z001 c003 t001 t005 z004 s002 a001 l1 a004 s003 vg103 t003 k001 m001, m002 m003 a005 t004 mastertig 2500w ac/dc 34.
Page 35: Structure
Structure a002 a001 vg101 l1 t001 z001 t002 z002 s001 m001 ga001 s002 c002 y001 a004 vg103 t003 t004 a005 m003 t005 k001 g002 mastertig 3500w ac/dc a003 35.
Page 36: Troubleshooting
Troubleshooting the machine may be repaired only by a workshop/technician licensed and authorized for the job! First do a visual check to find possible damage points, for example loose connectors broken wires or signs of overheating. Troubleshooting diagram problem possible cause remedy the power so...
Page 37: Troubleshooting Diagram
Troubleshooting diagram problem possible cause remedy the cooling unit doesn´t work. The cooling unit doesn´t start by the test switch. The missing coolant pressure warning lamp h001 is on.. The coolant will not circulate by the test switch sw301. The coolant doesn´t return to the reservoir. Fuse f0...
Page 38
Net voltage operational limits mastertig 2000 minimum maximum 230 vac 165 vac 270 vac mastertig 2500 minimum maximum 230 vac 175 vac 270 vac 400 vac 300 vac 460 vac 460 vac 340 vac 530 vac mastertig 3500 minimum maximum 400 vac 365 vac 460 vac signals between control card a001 (panel) and a002, x1 a...
Page 39
Process selection from the remote controller, voltage on connector x1/3 tig-process mma process temperature watch in room temperature (approx.. + 20º c) temperature watch, voltage on connector x1/4 fans on fan control, voltage on connector x1/6 dc+ 10 a, mma dc+ 200 a, mma dc+ 350 a, mma info of wel...
Page 40
Ac 10 a, mma ac 200 a, mma ac 350 a, mma info of welding current (dc+ and ac pos. Half-cycles), voltage on x1/9 + 15 v, mma + 30 v, mma + 70 v, mma info of welding current (dc+ and ac pos. Half-cycles), voltage on x1/11 15 vac, mma 30 vac, mma net voltage ok net overvoltage net overvoltage watch, vo...
Page 41
Torch start switch detection, voltage on connector x1/15 torch start switch open torch start switch closed 41.
Page 42
Ac tig-welding auxiliary pulse control, voltage on connector x1/16 ac tig-welding auxiliary pulse control ac tig-welding auxiliary pulse control 42.
Page 43
Solenoid valve y001 control, voltage on connector x2/1 solenoid valve open tig ignition spark control (if the arc is not on immediately, then controls will be on in 10 ms. Intervals for 2 seconds) tig hf-ignition spark control, voltage on connector x2/2 10 a 100 a 200 a 350 a set value from control ...
Page 44
Pwm-control enabling, voltage on connector x2/4 pwm enabled pwm disabled dc+ dc- secondary igbt control, voltage on connector x2/5 ac 50 hz, mma ac 200 hz, tig 44.
Page 45
Balance -70, tig balance +70, tig secondary igbt control, voltage on connector x2/5 cooling unit is off cooling unit is on cooling unit control, voltage on connector x2/13 45.
Page 46
Cooling unit monitorings, voltage on connector x2/14 cooling ok error, stop -command to cooling unit 36 khz 18 khz inverter frequency selection, voltage on connector x2/15 measurings from control card a002 connector x8 46.
Page 47
Tig ignition spark control (if the arc is not on immediately, then the controls are on in 10 ms. Intervals for 2 s.) tig ignition spark control, voltage on connector x8/1 torch start switch detection, voltage on connector x8/3 torch start switch open torch start switch closed 47.
Page 48
Measurings from control card a002 connector x9 solenoid valve open solenoid valve y001 control, voltage on connector x9/1-2 fan ”soft start” fan control, voltage on connector x9/3-4, 6-7 fan on 48.
Page 49
Information of secondary side voltage, voltage on connector x9/5 idling dc+, mma 100 a 200 a information of primary side current, voltage on connector x9/12-13 350 a 49.
Page 50
Measurings from control card a002 connector x10 dc+ dc- ac, mma / idling secondary igbt control, voltage on connector x10/1 ac 50 hz, mma ac 200 hz, tig 50
Page 51
Secondary igbt control, voltage on connector x10/1 balance -70, tig balance +70, tig without controller minimum maximum set value from remote controller, voltage on connector x10/7 mma tig process selection from remote controller, voltage on connector x10/9 51.
Page 52
Ac tig auxiliary pulse control, voltage on connector x10/10 ac-tig auxiliary pulse control measurings from control card a002 connector x11 cooling unit monitorings, voltage on connector x11/1 cooling ok error, stop -command to power source 52.
Page 53
Cooling unit control, voltage on connector x11/2 cooling unit is not on cooling unit is on measurings from control card a002 connector x20 net voltage ok net overvoltage, stop -command to power source net overvoltage measuring, voltage on connector x20/2 53.
Page 54
Measurings from control card a003 connector x3 dc+ dc- secondary igbt control, voltage on connector x3/1-4 ac, mma / idling ac 50 hz, mma 54.
Page 55
Ac 200 hz, tig secondary igbt control, voltage on connector x3/1-4 balance -70, tig balance +70, tig 55.
Page 56
Measurings from control card a003 connector x8 remote controller voltage reference, voltage on connector x8/2-4 min max set value from remote controller, voltage on connector x8/3-4 56.
Page 57
Process selection from remote controller, voltage on connector x8/1-4 mma tig mastertig 2000 ac/dc inverter controls igbt gate pulse control on mma / idling igbt gate pulses, voltage on connector x3/1-2 (a002) mastertig 2000 ac/dc 57.
Page 58
Igbt gate pulses, voltage on connector x3/1-2 (a002) igbt gate pulse control 10 a igbt gate pulse control 50 a mastertig 2000 ac/dc mastertig 2000 ac/dc 58.
Page 59
Igbt gate pulses, voltage on connector x3/1-2 (a002) igbt gate control 100 a igbt gate control 106 a (note! Frequency!) mastertig 2000 ac/dc mastertig 2000 ac/dc 59.
Page 60
Igbt gate pulses, voltage on connector x3/1-2 (a002) igbt gate control 160 a t001 primary voltage 10 a main transformer t001 primary voltage mastertig 2000 ac/dc mastertig 2000 ac/dc 60
Page 61
Main transformer t001 primary voltage t001 primary voltage 50 a t001 primary voltage 100 a mastertig 2000 ac/dc mastertig 2000 ac/dc 61.
Page 62
Main transformer t001 primary voltage t001 primary voltage 106 a (note! Frequency!) t001 primary voltage 160 a mastertig 2000 ac/dc mastertig 2000 ac/dc 62.
Page 63
After the diode card 10 a voltage after the diode cards after the diode card 50 a mastertig 2000 ac/dc mastertig 2000 ac/dc 63.
Page 64
Voltage after the diode card after the diode card 100 a after the diode card 106 a (note! Frequency!) mastertig 2000 ac/dc mastertig 2000 ac/dc 64.
Page 65: Secondary Voltage U
Voltage after the diode cards after the diode card 160 a tig u 2 10 k Ω 22 nf secondary voltage u 2 using a low-pass filter mastertig 2000 ac/dc 65.
Page 66: Secondary Voltage U
Secondary voltage u 2 using a low-pass filter ac 10 a 50 hz,mma ac 100 a 50 hz, mma mastertig 2000 ac/dc mastertig 2000 ac/dc 66.
Page 67: Secondary Voltage U
Secondary voltage u 2 using a low-pass filter ac 160 a 50 hz, mma ac 10 a 100 hz, tig (balance 50/50, balance automatics on) mastertig 2000 ac/dc mastertig 2000 ac/dc 67.
Page 68: Secondary Voltage U
Secondary voltage u 2 using a low-pass filter ac 50 a 100 hz, tig ac 100 a 100 hz, tig mastertig 2000 ac/dc mastertig 2000 ac/dc 68.
Page 69: Secondary Voltage U
Secondary voltage u 2 using a low-pass filter ac 160 a 100 hz, tig ac 200 a 100 hz, tig mastertig 2000 ac/dc mastertig 2000 ac/dc 69.
Page 70
Mastertig 2500 ac/dc inverter controls igbt gate pulses, voltage on connector x3/1-2 (a002) igbt gate control 10 a igbt gate control 100 a mastertig 2500 ac/dc mastertig 2500 ac/dc 70
Page 71
Igbt gate pulses, voltage on connector x3/1-2 (a002) igbt gate control 106 a (note! Frequency!) igbt gate control 250 a mastertig 2500 ac/dc mastertig 2500 ac/dc 71.
Page 72: Voltage Over A Lower Igbt
Voltage over a lower igbt voltage over the lower igbt 10 a voltage over the lower igbt 100 a mastertig 2500 ac/dc mastertig 2500 ac/dc 72.
Page 73: Voltage Over The Lower Igbt
Voltage over the lower igbt voltage over the lower igbt 250 a tig u 2 10 k Ω 22 nf secondary voltage u 2 using a low-pass filter mastertig 2500 ac/dc 73.
Page 74: Secondary Voltage U
Ac 10 a 50 hz, mma ac 100 a 50 hz,mma secondary voltage u 2 using a low-pass filter mastertig 2500 ac/dc mastertig 2500 ac/dc 74.
Page 75: Secondary Voltage U
Secondary voltage u 2 using a low-pass filter ac 250 a 50 hz, mma ac 10 a 100 hz, tig (balance 50/50, balance automatics on) mastertig 2500 ac/dc mastertig 2500 ac/dc 75.
Page 76: Secondary Voltage U
Secondary voltage u 2 using a low-pass filter ac 100 a 100 hz, tig ac 250 a 100 hz, tig mastertig 2500 ac/dc mastertig 2500 ac/dc 76.
Page 77
Mastertig 3500 ac/dc inverter controls igbt gate pulses, voltage on connector x3/1-2 (a002) igbt gate control on idle igbt gate control 10 a mastertig 3500 ac/dc mastertig 3500 ac/dc 77.
Page 78
Igbt gate pulses, voltage on connector x3/1-2 (a002) igbt gate control 100 a igbt gate control 106 a mastertig 3500 ac/dc mastertig 3500 ac/dc 78.
Page 79
Igbt gate pulses, voltage on connector x3/1-2 (a002) igbt gate control 200 a igbt gate control 350 a mastertig 3500 ac/dc mastertig 3500 ac/dc 79.
Page 80: Secondary Voltage U
Ac 10 a 50 hz, mma secondary voltage u 2 using a low-pass filter ac 100 a 50 hz, mma mastertig 3500 ac/dc mastertig 3500 ac/dc 80
Page 81: Secondary Voltage U
Secondary voltage u 2 using a low-pass filter ac 200 a 50 hz, mma ac 350 a 50 hz, mma mastertig 3500 ac/dc mastertig 3500 ac/dc 81.
Page 82: Secondary Voltage U
Secondary voltage u 2 using a low-pass filter ac 50 a 100 hz, tig (balance 50/50, balance automatics on) ac 100 a 100 hz, tig mastertig 3500 ac/dc mastertig 3500 ac/dc 82.
Page 83: Secondary Voltage U
Secondary voltage u 2 using a low-pass filter ac 200 a 100 hz, tig ac 350 a 100 hz, tig mastertig 3500 ac/dc mastertig 3500 ac/dc 83.