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

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 on the set value.
J03
TIG antifreeze
TIG antifreeze is on. TIG antifreeze is not on.
J04
AC balance
Manual AC balance adjustment. Balance automatics is on.
J05
Tacking automatics
Tacking automatics is disabled. Tacking automatics is enabled.
J06
Downslope cut-off
level
The downslope drops to minimum current
(3A DC, 10A AC).
The downslope drops to the end level,
which is 20% of the welding current.
J07
OCV
OCV is 39V. (22V/VRD) OCV is 70V.
J08
“china logic”
In the ending of the 4T function the
downslope is started by pressing the torch
switch. The downslope is on while the
switch is pressed, welding current is cut-off
when the switch is released. If it is pressed
for a longer time than the downslope, then
the current remains on the end current level
(see J06).
Normal 4T function.
J09
Inverter frequency
Inverter frequency is 18 kHz on the whole
current level.
Inverter frequency is 18kHz/36kHz on
MMA.
J10
2T hot/soft-start
Hot/soft–start is in use wit TIG 2T-function. Hot/soft–start is not in use with TIG 2T-
function.
J11
2T hot/soft–start
time adjustment
Hot/soft–start time with 2T-function.
Adjustment range is 0,0- 9,9 s.
J12
2T downslope
On 2T the downslope is not cut-off by a
short (nor long) press on the switch.
On 2T the welding is stopped by a short
pres on the switch during the downslope.
J13
AC-welding positive
half-cycle
On AC-TIG the height of the pos. half-cycle
is the same as the negative half-cycle´s
height.
On AC-TIG the height of the pos. half-
cycle depends on the set value and balance
adjustments.
J14
Start switch short
press
Torch switch short press time limit is 0,3 s. Torch switch short press time limit is 0,7 s.
J15
AC-TIG start cycle
AC-TIG-welding is started with a negative
half-cycle.
AC-TIG-welding is started with a positive
half-cycle.
J16
AC-TIG start cycle
length
Length adjustment for the DC start of the
positive half cycle in AC-TIG 0.0 .... 2.0.
Factory setting is 1.
J17
MMA ignition pulse
MMA ignition pulse height adjustment 0.0
..... 2.0.
Factory setting is 1.
J18 --
J19 --
11

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 power
sources, based on PWM-principle. Operating frequency is 18/36 kHz.
Mastertig AC/DC comes in three sizes; 1~ 200 A, 3~ 250 A and 3~ 350 A.
Mastertig AC/DC-power sources offer 3 different types of function panels; basic panel, minilog-
panel and pulse panel.
Mastertig AC/DC´s function are controlled by a microcontroller (panel mounted), so all
functions are carried out programmatically.
The operating principle of Mastertig AC/DC-power sources is shown below:
UG2
t
UG3
t
U1
t
C2
C3
V2
V3
T001
U1
UG2
UG3
The primary inverter is a traditional half-bridge, where the intermediate circuit DC is halved by
working capacitors C2 and C3.
When the upper IGBT (V2) is conductive, the primary transformer T001 primary has positive
voltage and when the lower IGBT (V3) is conductive, it is negative. Welding power is altered by
altering the transistor timings (PWM).
12

Operation principle
T001
R001
T003
V4
V6
TIG
V5
UG5
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+, is IGBT V5 conductive.
T001
R001
T003
V4
V6
TIG
V5
UG6
When current type is DC-, is IGBT V6 conductive.
13

Operation principle
T001
R001
T003
V4
V6
TIG
V5
UG5
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
EMI-filt.
Primary
rectifying Filtering
Primary
inverter
Main
transformer
Sec.
rectifying
Sec.
inverter
Spark transformer
P001
M
P
14

Filter cards
Information of overvoltage to
control cards A002 and A001
GND
+ 15 V
Control
To the primary rectifier
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/DC Z002
15

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, L3Intermediate circuit DC
L1, L2
Mastertig 3500 AC/DC Z002
The filter cards Z001 (2000) and Z002 (2500/3500) have overvoltage protection against low
energy voltage spikes coming from the net, an EMI-filter against electromagnetic disturbances
conducting to the net and net overvoltage watch. Chokes L005 (2000) and L006 (2500/3500)
also limit the electromagnetic disturbances conducting to the net. Auxiliary transformer T002
generates the needed voltages for control cards.
X1
X7
X6
X8
X5
X4
X2
X3
Filter card layout
Mastertig 2000 AC/DC Z001
Filter cards
16

Filter card layout
X3
X1
X15
X7
X5
X19
X24
X25
X22
X16
X13
X11
X9
R3
X23X18
Mastertig 2500 AC/DC Z002
X6
X7
X1
X20
X4
X5
X19 X2 X15 X21 X9 X8
X11
X10
X13X12X18X17X16X22X14
Mastertig 3500 AC/DC Z002 17

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 by current transformer T004.
Mastertig 2000 AC/DC Z002
The primary rectifier VG101 rectifies the net voltage. Primary choke L001 and smoothing
capacitor C003 filter the DC voltage. Primary inverter´s working capacitors are mounted onto
the main circuit card Z001.
Mastertig 2500 AC/DC Z001
18

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
X5
Mastertig 2000 AC/DC Z002 19

Main circuit cards layout
X2
X1
X3 X5 X4
X9
X7X6X8
Mastertig 2500 AC/DC Z001
X8
X53/E1
X5
X5
X4
X9 X9 X10 X7 X7
Mastertig 3500 AC/DC Z001 20