Kemppi MasterTig 3500 User manual

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

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 (1400-2200) 16
Voltage after the secondary diodes (1400-2200) 17
Troubleshooting 18-20
Power source control card A001 block diagram 21
Mastertig-power source´s TIG-section´s functions 22
Signals between control cards A001 and A002 23
Signals between control cards A002 and A004 23
Control card A001 layout (1400/1500) 24
Control card A001 layout (2000/2200) 24
Control card A001 layout (2800/3500) 25
MSD 1-meter unit layout 25
Control card A002 layout (1500/2200) 26
Control card A002 layout (2800/3500) 26
Control card A004 layout (2800/3500) 27
Control card A001 operation check 27
Control card A002 operation check 28-29
Control card A004 operation check 30
Notes 31
2

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~ 280 A and 3~ 350 A
General
Technical data, switches and connectors
1
2
3
1 Main switch S001 and welding current connectors
2 Overheat protection signal lamp
3 Current adj. potentiometer
Master 1400
Supply voltage 1∼,50/60 Hz
Connection power 20% ED
60% ED
100% ED
Supply cable/ fuses
220V –10%….240V +6%
140 A/ 6,2 kVA
105 A/ 4,4 kVA
75 A/ 2,9 kVA
3 x 1,5S / 16 A slow
Welding current range MMA
Suitable electrode sizes
Welding power adj.
15 A / 20,0 V..140 A / 25,6 V
∅1,5…..3,25 mm
stepless
OCV
Efficiency
Idling power
Approx. 80 V
80% (140 A / 25,6V)
Approx. 10 W
Degree of protection / Casing
class
IP 23
Weight 10 kg
3

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/ fuses
220V –10%….240V +6%
150 A / 6,6 kVA
105 A / 4,4 kVA
75 A / 3,0 kVA
3 x 1,5S / 16 A slow
Welding current range MMA
(TIG
Suitable electrode sizes
Welding power adjustment
15 A / 20,5 V..150 A / 26,0 V
5 A / 10,2 V..150 A / 16,0 V)
∅1,5…..3,25 mm
stepless
OCV
Efficiency
Idling power
Approx. 80 V
80% (150 A / 26,0 V)
Approx. 10 W
Degree of protection / Casing
class
IP 23C
Weight 10,5 kg (TIG, 13,5 kg)
Auxiliary devices Remote controllers
C 100C, C 100D
4

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
60% ED
100% ED
Supply cable / fuses
380V –10%….415V +6%
220 A / 8,4 kVA
145 A / 5,5 kVA
110 A / 3,5 kVA
4 x 1,5S / 10 A slow
Welding current range MMA
(TIG
Suitable electrode sizes
Welding power adjustment
15 A / 20,5 V…220 A / 28,8 V
5 A / 10,2 V…220 A / 18,8)
∅1,5…4,0 (5,0) mm
stepless
OCV
Efficiency
Idling power
Approx. 80 V
82% (220 A / 28,8V)
Approx. 10 W
Degree of protection / Casing
class
IP 23C
Weight 12,5 kg (TIG, 16 kg)
Auxiliary devices Remote controllers
C 100C, C 100D
5

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
1234
6
5
7
Supply voltage 3∼,50/60 Hz
Connection power 35% ED
60% ED
100% ED
Supply cable/ fuses
380V –10%….415V +6%
280 A / 11,5 kVA
213 A / 8,5 kVA
165 A / 6,0 kVA
4 x 1,5S / 10 A slow
380V –10%….415V +6%
350 A / 15,0 kVA
267 A / 11,0 kVA
207 A / 8,0 kVA
4 x 2,5S / 16 A slow
Welding current range MMA
(TIG
Suitable electrode sizes
Welding power adjustment
15 A / 20,5 V…280 A / 31,2 V
5 A / 10,2 V…280 A / 21,2 V)
∅1,5…n. 5,0 mm
stepless
15 A / 20,5 V…350 A / 34,0 V
5 A / 10,2 V…350 A / 24,0 V)
∅1,5…n. 6,0 mm
stepless
OCV
Efficiency
Idling power
Approx. 75 V
83% (280 A/ 31,2 V)
approx. 25 W
approx. 75 V
83% (350 A/ 34,0 V)
approx. 25 W
Degree of protection / Casing
class
IP 23 IP 23
Weight 22 kg (TIG, 27 kg) 25 kg (TIG, 30 kg)
Auxiliary devices Remote controllers
C 100C, C 100D, C100T,
MSD 1
Remote controllers
C 100C, C 100D, C100T,
MSD 1
6

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
2345
Pregas time Pause current Postgas time
2T/4T-selection
Ignition method and process selection
Downslope timePulse frequencyContinous / pulse
welding selection,
pulse ratio
adjustment
Pulse panel
7

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 selection and
pulse ratio adjustment
8

Mastertig 2800 and 3500
1
234
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
2T/4T-selection
Ignition method and process
selection
DownslopePulse frequencyContinous / pulse
welding selection,
pulse ratio
adjustment
Pulse panel
9

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 and
pulse ratio adjustment
10

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 the
upper IGBT (V2) is conductive, there is positive voltage in the main transformer´s (T1) primary,
and when the lower IGBT (V3) is conductive there is negative voltage in the main transformer´s
(T1) primary.
Power is adjusted by altering the IGBT timings (PWM). The main transformer (T1) secondary
voltages are rectified by a full-wave rectifier.
UG2
t
UG3
t
U1
t
U2
t
C2
C3
V2
V3
T1
U1
U2
UG2
UG3
approx. + 320 V (1~) or approx. + 570 V (3~)
Voltage over the lower IGBT V3 with minimum power (3~) Voltage over the lower IGBT V3 with maximum power (3~)
11

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

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 2800/3500)
B
B
13

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

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
15

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

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
DD
F
D
17

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.
DISTURBANCE POSSIBLE CAUSE REMEDY
The power source will not start.
MMA open circuit voltage is 0 V
Net fuses have blown
Faulty supply cable
Faulty main switch
Faulty current adjustment
potentiometer
Faulty local / remote control
selection switch (2200-3500)
Faulty auxiliary transformer
Faulty primary side power
semiconductor
Faulty control card A001
Faulty control card A002
(Mastertig)
Faulty flat cable between
control cards A001 and A002
Check the net fuses
Check the supply cable condition
Check the main switch condition
Check the potentiometer condition
Check the control method selection
switch condition
Check the auxiliary transformer
condition
Check the condition of the primary
rectifier and the IGBT-module
Check the control card A001
condition (see page 27)
Check the control card A002
condition (see pages 28 and 29)
Check the flat cable condition
(see page 23)
Faulty primary side power
semiconductor
Faulty main circuit card
Faulty secondary unit
Check the condition of the primary
rectifier and IGBT-module
Check the condition of the
smoothing and load capacitors.
Look for possible signs of
insulation damages on main circuit
card.
Check the secondary diodes
condition.
The net fuses blow during
startup.
Note! 1-phase Master- and Mastertig-power sources may blow net fuses
during the first startup, without being anything wrong in the power source. This
is because the DC-link capacitors have relatively high charging current! This
phenomenon is found especially with automatic fuses.
Troubleshooting diagram
18

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 A002
(Mastertig)
Faulty flat cable between
control cards A001 and A002
Check the net fuses
Check the supply cable condition
Check the main switch condition
Check the primary rectifier and
IGBT-module
Check the correct pulse ratio
adjustment from control card A001
to IGBT gate (see pages 12 and 15)
Check the main circuit card
capacitors and their connections
Check the condition the secondary
diodes
Check the main transformer ferrites
Check the flat cable signals
between control cards A001 and
A002; pins 1 and 2 against the
card´s GND (see pages 28 and 29)
Check the flat cable´s condition
(see page 23)
The power source will not
operate on TIG
Check power source´s operation on MMA. Disconnect the flat cable
from control card A001 and connect a shortcircuit loop to the flat cable
connector X3, between pins 1 and 2. If the power source doesn´t work
on MMA , then the TIG process can not work either.
Faulty flat cable between control
cards A001 and A002
Check the flat cable condition
(see page 23)
Faulty control card A002 Check control card condition
(see pages 28 and 29)
TIG-spark ignition doesn´t work.
Scratch ignition method is OK.
On MMA the machine works
OK.
Faulty flat cable between control
cards A001 and A002
Faulty control card A002
Faulty control card A004
(2800/3500)
Check the flat cable condition
(see page 23)
Check the control card A002
condition
(see pages 28 and 29)
Check the control card A004
condition (see page 30)
19

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 pages 28 and 29)
Mastertig 3500 W-cooling unit
doesn´t stay on, when operated
by it´s start switch
Faulty pressure switch
Faulty control card A005
Check the pressure switch
Check the control card A005 relays
Mastertig 3500 W-cooling unit
doesn´t start, when operated by
it´s start switch
The fuse F002 has blown
Faulty switch
Faulty auxiliary transformer
T004
Pump is jammed
Faulty startup capacitor
Faulty pump motor
Check the fuse and the fuse holder
Check the switch
Check the auxiliary transformer
T004
Check and clean the pump
Check the startup capacitor.
Check the pump motor
20