Kemppi MASTERTIG AC/DC 2500W 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 U2 using low-pass filter (2000)…..................65-69

Mastertig 2500 AC/DC inverter controls……….............70-73

Sec. voltage U2 using low-pass filter (2500)…................. 73-76

Mastertig 3500 AC/DC inverter controls……............….77-79

Sec. voltage U2 using 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

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

X4

X9 X9 X10 X7 X7

Mastertig 3500 AC/DC Z001 20

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