Kemppi mastertig acdc 1600 User manual

TECHNICAL SERVICE
MANUAL FOR MASTERTIG
ACDC MACHINES

TECHNICAL SERVICE MANUAL FOR MASTERTIG ACDC
INTRODUCTION / GENERAL MAINTENANCE OF MASTERTIG ACDC
Maintenance of the Mastertig ACDC machine would normally involve a general
check of the electrical connections of the machine, cleaning of the unit’s
interior with soft brush and vacuum cleaner and a physical check of parts such
as switches, connectors, potentiometers and fuses.
NOTE! If you use compressed air for cleaning, there is a risk that dirt may be
driven into pcb connectors and other components.
Maintenance of the power source and tig torch will normally consist; checking
of electric connections, general cleaning and change of consumable parts like:
gas nozzle, torch body, electrode and electrode shield, tightening bush and
housing for tighten bush and all isolating of torch body. Check also that flow of
the shielding gas is free and even. Due to high temperature the welding end of
TIG torch requires maintenance most. Check also the condition of the welding
and connection cables daily! Check also mains connection cables! Do not use
damaged cables!
The number of systems in operation and the importance of minimize not
running time will determine to what extend consumable- and spare parts will be
stocked. The amount of use and an unusual working enviroment have a
special effect on the need of maintenance.
WARNING !
DISCONNECT THE POWER SOURCE FROM MAINS SUPPLY VOLTAGE BEFORE REMOVING
SIDE PANELS. DANGEROUS DC VOLTAGE STILL EXISTS EVEN AFTER REMOVAL OF
MAINS SUPPLY. WAIT AT LEAST TWO MINUTES (RECOMMENDED DISCHARGE TIME FOR
CAPACITORS) BEFORE REMOVING THE CASING PLATES.
Troubleshooting
Start troubleshooting by looking for signs of over heating, fractures and
damage to internal components and power semiconductors. Visual inspection
before troubleshooting may help to isolate the defective circuit.

TECHNICAL SERVICE MANUAL FOR MASTERTIG ACDC
TROUBLESHOOTING CHART
PROBLEM CAUSE REMEDY
The MASTERTIG ACDC won’t start
at all. Internal water cooler not
operational
The signal lamps of machine are not
switched on and LEDs are not on in
the function panel.
Blown fuse(s) in mains supply line *).
Faulty main supply cable.
Faulty main switch S001.
Malfunctioning auxiliary transformer
T002 or loose connection.
Faulty EMC filter card Z002.
Check all three supply voltage
phases so that the fuses are not
blown, change if needed.
Check/repair faulty main supply
cable.
Check the main supply voltage
before and after main switch, change
switch if needed.
Check the transformers supply and 0
V lines, change T002 if needed.
Check the mains supply line voltage
from Z002. Change PCB if need.
When the machine is switched on
the cooling fan continuously rotates
and the function panel does not
work, the LED’s are not on.
Some functions from the panel are
not working.
Broken function panel or loose
connection between panel and PCB
A002.
Check the flat cables and connectors
from panel and A002, X1 and X2.
Change the function panel if needed.
NOTE! IF SOME FUNCTIONS OF PANEL
ARE MISSING, OR IT IS NOT WORKING
PROPERLY CHANGE THE PANEL
MEMBRANE
The machine will not start, and the
signal LED in function panel for
over/under/wrong supply voltage is
switched on.
Uin Err message in the main
display
The machine is connected to wrong
supply voltage.
Unplug the machine from the mains
supply and select the correct voltage
from the voltage change-over switch
which is located under the function
panel.
Short breaks in the welding arc and
over/under/wrong supply voltage
LED is on during these breaks
Overvoltage in mains supply line. Check the mains supply line. The
approx. voltage limits are mentioned
in TABLE 4.
*) Main supply line fuse(s) burned. Faulty main supply cable.
Short circuit in primary part of the
machine.
Short circuit in secondary part of the
machine.
Check/repair faulty main supply
cable.
Check/change the main switch,
primary rectifier, primary IGBT unit
and inverse parallel diode.
Check/change the secondary rectifier
unit (diode blocks) and secondary
IGBT unit. See also
TROUBLESHOOTING FOR
POWER SEMICONDUCTORS.
Err 1 message in the main display. Secondary voltage of machine has
been over 90 volts more than 4
seconds.
IGBT V47, which is located in control
card A003 PICTURE 1., is faulty.
Check and change the pcb or IGBT.

TECHNICAL SERVICE MANUAL FOR MASTERTIG ACDC
TROUBLESHOOTING CHART
PROBLEM CAUSE REMEDY
The cooling unit is not operational
or H001 light is on.
The water doesn’t circulate by switch
SW302.
Water doesn’t return back to the
tank.
Blown fuse F002 2A.
Broken or faulty auxiliary-
transformer T005.
Broken pressure switch S002.
Pressure switch set value is
unsuitable for the TIG torch which
is in use (other than original Kemppi
torch).
Air bubbles in the system.
Leakages in the cooling system.
Pump motor 5µstarting capacitor
C004 is faulty.
Broken or faulty PCB A005 .
Check and change the fuse if
needed.
Check first the supply voltage of
transformer from Z004, connector
1=230V, 2=400, and 3=460V. Then
check the secondary voltage of
transformer, check it from terminal
block XW301 between 4 an 5 the
voltage is c. 230 VAC.
Check the voltage over the pressure
switch or from PCB A005 X2/1 and
X2/8; enough pressure 0V and lack
of pressure c. 5V.
Adjust the pressure set value from
the adjustment screw, of pressure
switch according following
instructions:
I START PRESSING TEST SWITCH
SW302 AND ADJUST THE ADJUSTMENT
SCREW (SEE PICTURE 3.) FOR
PRESSURE, IN SUCH WAY THAT THE
SIGNAL LAMP H001 IS ONLY JUST
SWITCHED OFF.
II RELEASE SWITCH SW302 AND WAIT
FOR APPR. 10 S AND CHECK THAT
SIGNAL LAMP H001 IS NOT FLASHING.
III STILL CHECK BY WELDING FOR
APPROX. 20 S THAT THERE ARE NO
MORE DISTURBANCES.
Blow compressed air into tank,
closing the filling hole by hands is
enough.
Check/repair the connection of
cooling system connector by
connector. Repair the system if
needed.
Check and change the capacitor if
needed.
Change/repair PCB A005.
The solenoid valve Y001 is not
operating // stuck open
Faulty solenoid valve Y001 or
broken PCB A002.
Check the 24 VDC from A002
connector X9 between pins 1and 2.
If it is ok, change the solenoid valve.

TECHNICAL SERVICE MANUAL FOR MASTERTIG ACDC
TROUBLESHOOTING CHART
PROBLEM CAUSE REMEDY
Remote control unit is not operating
properly.
Defective remote control unit, faulty
control cable or faulty control card
A003 in Mastertig ACDC.
Faulty function panel.
Selection for remote unit type is not
correct.
Fuse F001, 0.8A, blown.
Check and repair the remote control
unit and cable according to TABLE
3.
Change PCB A003 in Mastertig
ACDC.
Check the function panel, see
TABLE 1, that the switching for
selection for local/remote is working.
Change the panel membrane if
needed.
See the paragraph SELECTION OF
REMOTE CONTROL UNIT.
Check and change the fuse if
necessary.
Machine is overheating. Signal lamp
for thermal protection is on even if
the duty-cycle time has not been
exceeded.
Faulty cooling fan(s) or PCB A002.
Loose connector.
Check the 24 VDC voltage from fan
connectors: X9 between pins 3 and
4, another between 6 and 7, if it is
all right change the fan(s), if it is
not change the PCB.
There are occasional disturbances
during welding, set value is not
stable or arc is intermittent.
Arc is stopping intermittently.
Remote control unit is faulty
Faulty start switch in TIG torch.
Broken/faulty TIG torch, loose start
wire(s) in TIG torch.
Faulty Reed relay, K001.
Check/repair the control cable and
remote control unit according to
TABLE 3.
Check and change the start switch if
needed. See also TABLE 2.
Check and tighten the start wire(s)
inside the TIG torch.
Check it by opening the connector
X009, change reed relay if needed.
Welding quality is bad in all methods:
•arc is not stable
•bad arc start
•not enough arc voltage
•lack of power
One mains phase is missing or
mains cable is cut or loose.
Faulty main switch, S001, or primary
rectifier, VG101/G001.
Faulty capacitor C003.
Blown diode(s) in the secondary
rectifier G002, G003 or G004.
Gas is missing or gas leakage in the
TIG torch.
Broken/untightened earth cable or
earth clamp.
Check all mains phases from
terminal block X001. Change mains
fuse if needed, tighten mains cables.
Check using multimeter that S001 is
all right, check also that all diodes in
primary rectifier are functional.
Check/change capacitor C003.
Check and change diode blocks
according to APPENDIX 1.
Check gas flow and solenoid valve
as described earlier. Repair/change
TIG torch if needed.
Check and change the earth clamp
and the cable if necessary.

TECHNICAL SERVICE MANUAL FOR MASTERTIG ACDC
TROUBLESHOOTING CHART
PROBLEM CAUSE REMEDY
Porosity in the weld joint. Shield gas flow is not correct,
leakage in the gas hose or faulty
solenoid valve.
Check the gas flow; adjust correct
flow according welding parameters
or repair faulty component in gas
flow system.
No HF ignition Faulty control card A004.
Broken HF-transformer T003.
During HF ignition the voltage from
connector X1/1 and X1/3 should be
about 1kV. You can also check the
control signal of microprocessor from
connector X2/2 which is located
between panel and PCB A002.
If the voltage from PCB is all right
change the HF-transformer T003.
Welding characteristics are bad
when welding method is AC TIG.
Additional pulse to ignite the positive
half cycle is missing.
Check the function of control card
A003. The pulse circuit driving
component is small IGBT V47.
Check and change the IGBT if
needed.
Positive or negative half cycle is
missing, or both are missing.
Machine is creating high pitched or
rattling sound.
Faulty control card A002 or A003.
Faulty IGBT in primary or secondary
inverter.
Faulty gate IGBT connection in
control card A002 or A003.
Check that control of selecting
welding method is working from the
PCB A003, see PICTURE 1.
Check according following text;
Primary inverter is VG 101.
When the current goes through
VG201 the method is DC+. If the
current goes through VG202 the
method is DC-. When the current
goes through both of them the
method is AC.
See also PICTURE 4.
If security code is in use and panel is
locked.
Wrong security code. The locked panel can be unlocked at
an authorised KEMPPI service repair
shop with a special code . The
unlock code is available only in
these places.
Maximum positive or negative
current adjustment is incorrect.
Wrong/changed adjustment in
control card A002.
Maximum positive and negative
current can adjust from A002, see
also PICTURE 2.

TECHNICAL SERVICE MANUAL FOR MASTERTIG ACDC
TABLE OF JUMPERS, EXTRA FUNCTIONS.
In addition to the standard Master-tig functions there are some extra features
which may be called up by using the so called ‘electronic jumpers’. These
jumpers may be set to tailor the machine to the customer’s needs and include
the following;
JUMPER NUMBER FUNCTION ON FUNCTION OFF
J01
UP SLOPE
UP SLOPE TIME DEPENDS ON
SET VALUE OF CURRENT
UP SLOPE TIME IS INDEPENDENT OF SET
VALUE OF CURRENT
J02
DOWN SLOPE
DOWN SLOPE TIME DEPENDS
ON SET VALUE OF CURRENT
DOWN SLOPE TIME IS INDEPENDENT OF
SET VALUE OF CURRENT
J03
TIG ANTIFREEZE
TIG ANTIFREEZE IS ON TIG ANTIFREEZE IS OFF
J04
AC BALANCE
MANUAL AC BALANCE
CONTROL IS IN USE
SMART BALANCE FUNCTION IS IN USE,
SCALE OF PANEL IS IN USE
J05
TACK WELDING
TACK WELDING IS AUTOMATIC DOWN SLOPE FUNCTIONS IMMEDIATELY
J06
DOWN SLOPE CUT OFF
LEVEL
DOWN SLOPE CUT OFF LEVEL
IS MINIMUM CURRENT
DOWN SLOPE CUT OFF LEVEL IS 20 %
OF SET VALUE
J07
OPEN CIRCUIT VOLTAGE
OPEN CIRCUIT VOLTAGE
IS 70 V
OPEN CIRCUIT VOLTAGE IS C. 39.5 V
J08
“CHINA LOGIC”
TIG WELDING IN 4T
POSSIBILITY TO PRESET
STARTING CURRENT,
WELDING CURRENT AND
END CURRENT
NORMAL 4T FUNCTION
J09
Inverter Frequency
INVERTER FREQUENCY IS 18
KHZ IN THE WHOLE CURRENT
RANGE
INVERTER FREQUENCY IS 18 KHZ/ 36
KHZ IN MMA!
J10
2T Hot/ soft start
HOT/ SOFT START IS IN USE
WITH TIG 2T LOGIC
J11
2T Hot/ soft start time
setting
HOT/ SOFT START TIME IN 2T
LOGIC. ADJUSTMENT RANGE
IS 0,0-9,9 SECONDS
J12
2T Downslope
IN 2T THE DOWNSLOPE
DOESN´T END WITH A SHORT
OR A LONG PULL, SO THE
WELDING CURRENT CAN BE
TAKEN UP AND DOWN WITH A
SHORT PULL ON THE TRIGGER
IN 2T THE WELDING IS ENDED DURING
DOWNSLOPE WITH A SHORT PULL ON
THE TRIGGGER
J13-15 NOT IN USE
JO16
POSITIVE START CYCLE OF
AC-TIG
ADJUSTMENT FOR LENGTH OF
POSITIVE START CYCLE,
FACTOR 0.0 2.0
FACTORY SETTING IS 1
JO17
MMA IGNITION PULSE
ADJUSTMENT OF MMA
IGNITION PULSE (0,0-2,0)
FACTORY SETTING IS 1

TECHNICAL SERVICE MANUAL FOR MASTERTIG ACDC
SELECTION OF REMOTE CONTROL UNIT
1. Turn off the machine.
2. Press the REMOTE key and at the same time turn the machine on; the display
will show the text rEn 01. The machine is now selected to use for hand held
remote control units (C 100C, C 100D, or C 100AC).
3. Turn the current adjustment knob so that the display shows rEn 02.
The machine is now selected to use foot controlled remote unit (C 100F).
4. Press the REMOTE key so that the setting is saved in the memory.
CALIBRATION OF THE PANEL
It is possible to calibrate the current meter of the Mastertig ACDC in DC -
and DC + at two different points, 10 A and 100A. If you want to calibrate the
current setting of the machine you will need a shunt resistor, loading bench
and multimeter to monitor real current value.
1. First set machine polarity to DC - and note the meter readings when set
value is 10 A and 100 A. Repeat this process for DC + polarities
2. Turn off the machine.
3. Press the POST GAS key and at the same time turn the machine on.
4. Press the BROKEN ARC key; display will show text CU1 010. Now you
can feed in, by the current adjustment knob, the real measured value for
DC - 10 A.
5. By pressing the REMOTE next time display will show text CU2 100,you can
now feed in the measured DC -100 A value.
6. Repeat same with DC +, CU3 010 is for DC + 10 A and CU4 100 is for
DC + 100 A.
7. Press the POST GAS key so that the calibration setting is saved in the
memory.
8. Check the corrected values from the panel display.

TECHNICAL SERVICE MANUAL FOR MASTERTIG ACDC
TABLE 1. FUNCTION SIGNALS CONNECTORS X1 AND X2 OF PCB A001
PIN NUMBER DESCRIPTION
X1
X1/1 IDENTIFICATION OF THE SIZE OF THE MACHINE
X1/2 SET VALUE FROM THE REMOTE CONTROL UNIT
X1/3 SELECTION OF METHOD FROM THE REMOTE CONTROL UNIT
X1/4 THERMAL PROTECTION(PTC)
X1/5 NOT IN USE
X1/6 CONTROL OF COOLING FANS
X1/7 CONTROL OF MAINS SUPPLY VOLTAGE FROM T002 SECONDARY WINDING
X1/8 NOT IN USE
X1/9 WELDING CURRENT ; POSITIVE HALF-CYCLES OF DC+ OR AC
X1/10 WELDING CURRENT ; NEGATIVE HALF-CYCLES OF DC- OR AC
X1/11 WELDING VOLTAGE ; NEGATIVE HALF-CYCLES OF DC- OR AC
X1/12 WELDING VOLTAGE ; POSITIVE HALF-CYCLES OF DC+ OR AC
X1/13 CONTROL OF MAINS VOLTAGE
X1/14 OVER CURRENT
X1/15 SWITCH OF TIG TORCH
X1/16 ADDITIONAL AC PULSE FOR TIG
X2
X2/1 SOLENOID VALVE
X2/2 CONTROL OF TIG SPARK
X2/3 NOT IN USE
X2/4 PWM POSSIBLE
X2/5 CONTROL OF SECONDARY IGBT
X2/6 CONTROL OF SECONDARY IGBT
X2/7 +16 V
X2/8 +15 V
X2/9 +5 V
X2/10 +5 V
X2/11 GND
X2/12 GND
X2/13 START OF COOLING UNIT
X2/14 STOP OF COOLING UNIT
X2/15 NOT IN USE
X2/16 NOT IN USE

TECHNICAL SERVICE MANUAL FOR MASTERTIG ACDC
TABLE 2. CONNECTOR XW101 IN MASTERTIG ACDC
PIN NUMBER SIGNAL VALUE DESCRIPTION
A3.5 VAC start not active
0 V start is active
Torch start switch
B3.5 VAC start not active
0 V start is active
Torch start switch
C--
D--
TABLE 3. CONNECTOR XW102 IN MASTERTIG ACDC
PIN NUMBER SIGNAL VALUE DESCRIPTION
A--
B30 VAC Operating voltage for external
equipment, fuse 0.8 A
C30 VAC Operating voltage for external
equipment, fuse 0.8 A
D--
E+5 VDC Voltage reference of remote control
(upper end of the potentiometers)
F0 V GND (lower end of potentiometers)
G--
H0 - +5 VDC Set value for power source
I+2 VDC=TIG
+5 VDC=MMA
Selection of characteristic TIG/MMA curve
J--
TABLE 4. OVER AND UNDER VOLTAGE LIMITS, (WHEN OCV)
SUPPLY VOLTAGE LOWER LIMIT UPPER LIMIT
MASTERTIG ACDC 1600
230 VAC 165 VAC 270 VAC
MASTERTIG ACDC 2500
230 VAC 175 VAC 270 VAC
400 VAC 300 VAC 460 VAC
460 VAC 340 VAC 530 VAC
MASTERTIG ACDC 3500
400 VAC 365 VAC 460 VAC

TECHNICAL SERVICE MANUAL FOR MASTERTIG ACDC
PICTURE 1. LEDS IN PCB A003
LEDs, are on when machine is generating OCV
H1 H1 IS ON WHEN THE MACHINE IS IN DC- TIG OR MMA
H2 H2 IS ON WHEN THE MACHINE IS IN AC OR DC + TIG OR MMA
MASTERTIG AC/DC A003
H1
H2
X1
T3
T2
T1
X8
X5
X3
V
47
L1
X
4
X
10
X12
X11
X7
R57
R77

TECHNICAL SERVICE MANUAL FOR MASTERTIG ACDC
PICTURE 2. TRIMMERS IN PCB A002
MASTERTIG AC/DC A002
F2 F4
X2
0
X14
X9
X
11
X4X3
T1
X2
X1
X1
0
X8
N4 N1 N2
R44
R118
R119
X22
X5
X6
X7
TRIMMERS
R44 ADJUSTMENT FOR BASIC FREQUENCY
R118 ADJUSTMENT FOR DC- MAX CURRENT
R119 ADJUSTMENT FOR DC+ MAX CURRENT

TECHNICAL SERVICE MANUAL FOR MASTERTIG ACDC
PICTURE 3. PRESSURE ADJUSTMENT SCREW
*
* Adjustment screw for adjusting correct set value for pressure
PICTURE 4. MAIN CIRCUIT OF MASTERTIG ACDC
G001
S001
VG101
R001
T003
T001
VG201
VG202
X004
X005
G002
L001
( TIG )
( MMA )

TECHNICAL SERVICE MANUAL FOR MASTERTIG ACDC
APPENDIX 1.
CHANGING THE SET OF DIODES IN SECONDARY RECTIFIER
OF MASTERTIG ACDC
Rectifier diodes in Mastertig ACDC are plastic case types (2 x 15 A) These are
mounted with pressure bars ensuring good thermal transfer to the heat sink.
Individual diodes can not be changed because they are specially selected for
parallel connection using a forward voltage measurement hence only diodes
with the same characteristics can be used. This means that if one diode is
failed the whole set of diodes must be changed!
The mounting torque for tightening screw of pressure bar is 3.0 Nm. The
amount of silicon paste used should not be excessive because electrical
contact is made through the mounting surface of components.

MASTERTIG AC/DC 1600 27.11.2001/V161601 1027620 C/1916140
Order no. Part Description Pc.
4295710
A
002 CONTROL CARD A002 MASTERTIG AC/DC 1
4277540
A
003 CONTROL CARD MAS.TIG AC/DC A003 1
4280540
A
004 CONTROL CARD MAS.TIG AC/DC A004 1
4283150 C001 CAPACITOR C001 AC/DC 1
9772516 F001 FUSE 0,8A DELAYED 5 X 20 1
9772551 FUSE BOX + NUT 1
4281530 GA001 DIODE CARD 1
4286000 VG101 SPARE PART IGBT 1
9750126 VG102 DIODE BRIDGE 1
4280860 G001 PRIMARY UNIT 1
3139530 G002 SECONDARY UNIT 1
4290890 VG201 IGBT, SECONDARY AC/DC 1
4280880 G003 SECONDARY UNIT G003 MTIG 1600 ACDC 2
3140270 L001 PRIMARY CHOKE 1
9777115 L003 FERRITE RING 25/15 X 10 1
9544213 M001 COOLING FAN MASTER 1500/2200 1
4260200 R001 SHUNT RESISTOR MASTER 1500/2200 1
9761221 S001 FLIP-FLOP SWITCH WITH PILOT LAMP 1
2067620 T001 MAIN TRANSFORMER 1
9777825 T002 AUXILIARY TRANSFORM. 1
2067590 T003 SPARK TRANSFORMER 1
9777537 T004 CURRENT TRANSFORMER 1:250 PRO 1
9770105 XW101 CONTROL CONNECT. 4 POLES, FEMALE 1
9770116 XW102 MACHINE SOCKET 1
4292780 X003 CONIC COUPLING R 1/4-M 8X1 1
9771530 X004 MACHINE SOCKET 50/70 1
9771530 X005 MACHINE SOCKET 50/70 1
4262810 X006 FLAT CABLE L=175 1
9563002 Y001 SOLENOID VALVE 1
9755615 ZC213 CAPACITOR 470 UF 1
4281560 Z001 FILTER CARD 1
4282130 Z002 MAIN CIRCUIT CARD 1
4282300 001 RUBBER 1
3134270 002 HOSE CONNECTOR R1/8-M12 1
4286030 003 GAS CONNECTOR 1
9377205 004 HOSE CLAMP 1
9370182 005 PLASTIC HOSE 5/8 BLUE 0,25
2067100 006 FOOT 1
2067120 007 HANDLE MTIG 1600/2500 AC/DC 1
4280870 008 HANDLE 1
2067130 009 PROTECTIVE COVER MTIG 1600/2500 AC/DC 1
3139460 010 PLASTIC PIECE 1
4296190 011 STICKER MASTERTIG AC/DC 1
2067260 012 SIDE PLATE LEFT MTIG1600 ACDC 1
2067270 013 SIDE PLATE RIGHT MTIG1600 ACDC 1
3139520 014 COVER MTIG1600 ACDC 1
3133020 015 FOOT F COOL.PROFIL 1
4280560 016 FAST.PC F COOL.PROF. 1
3140350 CIRCUIT DIAGRAM MASTERTIG 1600AC/DC 1
9770456 PLUG 2 POLES 1
9770457 PLUG 3-POLES 1
9770458 PLUG 6 POLES 1
9770460 PLUG 15 POLES 1
9770462 CONTACT , MALE 1
9770464 CONTACT, FEMALE 1