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