Kemppi MASTERTIG AC/DC 2000 Manuel utilisateur

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

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

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

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

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

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

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

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