Kemppi MASTERTIG AC/DC 2000 User manual

Service manual
Ver. 1.0

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…………………………………………….14
Filter cards……………………………………..…………15, 16
Filter card layout………………………...........………… 16, 17
Main circuit cards………………………………………..18, 19
Main circuit cards layout………………………………...19, 20
Voltage selector switch (2500)………………………… 21
Secondary circuit components…………………………..21, 22
Diode card layout……………………………………...…23
Cooling unit…………………………………………….... 23
Filter card Z004 layout………………………………......24
Cooling unit control card A005………………….........…24
Control card A005 layout………………………………..25
Control card A001 functions………………………….....25
Control card A001 connectors………………………….. 26
Control card A002 functions and connectors…..………27, 28
Control card A002 layout………………………………. 29
Control card A003 functions and connectors…………..30
Control card A003 layout………………………………. 31
Control card A004 functions and connectors…………..32
Control card A004 layout…………………………….….32
Structure ……………………………………………..….. 33-35
Troubleshooting………………………………………..... 36, 37
Net voltage functional limits…..............................………38
Signals between control cards A001 and A002…………38-46
Measurings from control card A002 connector X8….…46, 47
Measurings from control card A002 connector X9….....48, 49
Measurings from control card A002 connector X10…...50-52
Measurings from control card A002 connector X11…...52, 53
Measurings from control card A002 connector X20…...53
Measurings from control card A003 connector X3…….54, 55
Measurings from control card A003 connector X8….....56, 57

Contents
Mastertig 2000 AC/DC inverter controls……….............57-65
Sec. voltage U2using low-pass filter (2000)…..................65-69
Mastertig 2500 AC/DC inverter controls……….............70-73
Sec. voltage U2using low-pass filter (2500)…................. 73-76
Mastertig 3500 AC/DC inverter controls……............….77-79
Sec. voltage U2using low-pass filter (3500)…................. 80-83

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
Welding 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 A / 26,4 V
AC 11 A / 10 V … 160 A / 26,4 V
Connection cable 3 x 2,5 mm2 S- 3
Fuse 16 A Slow
Loadability** TIG AC 30 % ED ( T = 40 C) 200 A / 18 V
100 % ED ( T = 40 C) 150 A / 16 V
MMA 20 % ED ( T = 40 C) 160 A / 26,4 V
100 % ED ( T = 40 C) 100 A / 23,6
Fuse 20 A Slow
Loadability*** TIG AC 50 % ED ( T = 40 C) 200 A / 18 V
100 % ED ( T = 40 C) 150 A / 16 V
MMA 60 % ED ( T = 40 C) 160 A / 26,4 V
100 % ED ( T = 40 C) 140 A / 23,6
OCV DC and AC 70 V DC
AC Frequency Fixed/adjustable 60 Hz / 50 … 200 Hz
Efficiency 75 % ( 160 A / 26,4 V )
Power factor 0,8 ( 160 A / 26,4 V )
Idling power 18 W
Temp class/degree of protection B ( 130 C ) H ( 180 C )/ IP 23 C
*) Adjustable in minilog and pulse panels
**) fuse size limits the loadability
***) 20 A fuse requires the change of the supply cable
4

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 280 A / 11,2 kVA
Fuse 230 V 20 A Slow
400 V 16 A Slow 20 A Slow
460 V 16 A Slow
W elding current range TIG DC 3 A / 10 V … 250 A / 20 V 3 A / 10 V … 350 A / 24 V
TIG AC 10 A / 10 V … 250 A / 20 V 10 A / 10 V … 350 A / 24 V
MMA DC 10 A / 20 V … 250 A / 30 V 10 A / 20V … 350 A / 34 V
MMA AC 10 A / 20 V … 220 A / 30 V 10 A / 20V … 350 A / 34 V
OCV 70 V DC 70 V DC
AC frequency Fixed/adjustable 60 Hz / 50 … 200 Hz 60 Hz / 50 … 200 Hz
Efficiency 80 % ( 250 A / 30 V ) 80 % ( 350 A / 34 V )
Power factor 0,9 ( 250 A / 30 V ) 0,9 ( 350 A / 34 V )
Temp class B ( 130 C ) H ( 180 C ) B ( 130 C ) H ( 180 C )
Degree of protection IP 23 C IP 23 C
Dimensions L, W, H (mm) 690 x 260 x 550, 830 690 x 260 x 870
Weight Kg 39 / 65 74
Coolant max. press. 350 kPa 350 kPa
Cooling unit power 1300 W 1300 W
5

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
Welding current connection
Return current connection
Control cable connection, remote controller
Control cable connection, TIG-torch
Supply cable
Main switch
Mastertig 2500 AC/DC
6

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 connector
Control cable connection, remote controller
Supply cable
Main switch
Mastertig 3500W AC/DC
7

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.
5 Current adj. knob/parameter adjustment
6 Local-/remote control selection/code lock
12 Pregas time adjustment/code lock
13 Welding current upslope adjustment 0…5 s.
14 2T/4T-selection
19 Broken arc
21 MMA welding selection
Basic panel
8

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-function selection/adjustment -80…+20 %
12 Pre gas time adjustment/code lock
13 Welding current upslope time adjustment 0…5 s.
14 2T/4T-selection
19 Broken arc welding
20 MMA welding dynamics adjustment
21 MMA welding selection
22 AC-TIG balance adjustment -70…+70 %
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
7 Pulse-TIG pulse height adjustment 3…200, 250,
350 A/pulse ratio adjustment 10…75 %
8 Pulse-TIG selection
9 Pulse-TIG background current adjustment 20…40 %/
frequency adjustment 0,1…300 Hz
10 Start current adjustment-70...+70 %
11 Minilog-function selection/adjustment -80…+20 %
12 Pregas time adjustment/code lock
13 Welding current upslope time adjustment 0…5 s.
14 Fusion spot welding selection/adjustment 0…10 s.
15 2T/4T-selection
16 Memory channels selection
17 Welding values saving into the memory channels
18 Memory channel selection
19 Broken arc welding
20 MMA welding dynamics adjustment
21 MMA welding selection
22 AC-TIG balance adjustment -70…+70 %
Minilog-panel
Pulsepanel
9

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 source by the main switch
2. Press and hold down the post gas button (3) and simultaneously turn the main switch S001 to
ON.
3. Press the pregas button(12) once. J01 is shown on the display.
4. Choose the jumper to be adjusted by REMOTE (6) button.
5. Change the jumper setting by the current adjustment knob (5).
6. To save the settings, finally press the post gas time (3) button.
Jumper functions
10