Witam, jak w temacie dokumentacje serwisowe do Kemppi MasterTig AC/DC.
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
Blown fuse(s) in mains supply line *).
Check all three supply voltage
phases so that the fuses are not
blown, change if needed.
The signal lamps of machine are not
switched on and LEDs are not on in
the function panel.
Faulty main supply cable.
Check/repair faulty main supply
cable.
Faulty main switch S001.
Check the main supply voltage
before and after main switch, change
switch if needed.
Malfunctioning auxiliary transformer
T002 or loose connection.
Check the transformers supply and 0
V lines, change T002 if needed.
Faulty EMC filter card Z002.
Check the mains supply line voltage
from Z002. Change PCB if need.
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
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.
The machine will not start, and the
signal LED in function panel for
over/under/wrong supply voltage is
switched on.
PROPERLY CHANGE THE PANEL
MEMBRANE
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.
Check/repair faulty main supply
cable.
Short circuit in primary part of the
machine.
Check/change the main switch,
primary rectifier, primary IGBT unit
and inverse parallel diode.
Short circuit in secondary part of the
machine.
Check/change the secondary rectifier
unit (diode blocks) and secondary
IGBT unit. See also
TROUBLESHOOTING FOR
POWER SEMICONDUCTORS.
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.
Uin Err message in the main
display
Err 1 message in the main display.
TECHNICAL SERVICE MANUAL FOR MASTERTIG ACDC
TROUBLESHOOTING CHART
PROBLEM
CAUSE
REMEDY
The cooling unit is not operational
or H001 light is on.
Blown fuse F002 2A.
Check and change the fuse if
needed.
Broken or faulty auxiliarytransformer T005.
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.
Broken pressure switch S002.
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.
Pressure switch set value is
unsuitable for the TIG torch which
is in use (other than original Kemppi
torch).
Adjust the pressure set value from
the adjustment screw, of pressure
switch according following
instructions:
Air bubbles in the system.
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.
Leakages in the cooling system.
Blow compressed air into tank,
closing the filling hole by hands is
enough.
The water doesn’t circulate by switch
SW302.
Water doesn’t return back to the
tank.
Check/repair the connection of
cooling system connector by
connector. Repair the system if
needed.
Pump motor 5µ starting capacitor
C004 is faulty.
Broken or faulty PCB A005 .
The solenoid valve Y001 is not
operating // stuck open
Check and change the capacitor if
needed.
Change/repair PCB A005.
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.
Check and repair the remote control
unit and cable according to TABLE
3.
Change PCB A003 in Mastertig
ACDC.
Faulty function panel.
Selection for remote unit type is not
correct.
Fuse F001, 0.8A, blown.
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.
There are occasional disturbances
during welding, set value is not
stable or arc is intermittent.
Remote control unit is faulty
Check/repair the control cable and
remote control unit according to
TABLE 3.
Arc is stopping intermittently.
Faulty start switch in TIG torch.
Check and change the start switch if
needed. See also TABLE 2.
Broken/faulty TIG torch, loose start
wire(s) in TIG torch.
Check and tighten the start wire(s)
inside the TIG torch.
Faulty Reed relay, K001.
Check it by opening the connector
X009, change reed relay if needed.
One mains phase is missing or
mains cable is cut or loose.
Check all mains phases from
terminal block X001. Change mains
fuse if needed, tighten mains cables.
Faulty main switch, S001, or primary
rectifier, VG101/G001.
Check using multimeter that S001 is
all right, check also that all diodes in
primary rectifier are functional.
Faulty capacitor C003.
Check/change capacitor C003.
Blown diode(s) in the secondary
rectifier G002, G003 or G004.
Check and change diode blocks
according to APPENDIX 1.
Gas is missing or gas leakage in the
TIG torch.
Check gas flow and solenoid valve
as described earlier. Repair/change
TIG torch if needed.
Broken/untightened earth cable or
earth clamp.
Check and change the earth clamp
and the cable if necessary.
Welding quality is bad in all methods:
•
•
•
•
arc is not stable
bad arc start
not enough arc voltage
lack of power
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.
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.
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.
Broken HF-transformer T003.
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.
Faulty control card A002 or A003.
Check that control of selecting
welding method is working from the
PCB A003, see PICTURE 1.
Faulty IGBT in primary or secondary
inverter.
Check according following text;
Machine is creating high pitched or
rattling sound.
Faulty gate IGBT connection in
control card A002 or A003.
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 TIME DEPENDS ON
SET VALUE OF CURRENT
UP SLOPE TIME IS INDEPENDENT OF SET
VALUE OF CURRENT
DOWN SLOPE
DOWN SLOPE TIME DEPENDS
ON SET VALUE OF CURRENT
DOWN SLOPE TIME IS INDEPENDENT OF
SET VALUE OF CURRENT
J03
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 IS AUTOMATIC
DOWN SLOPE FUNCTIONS IMMEDIATELY
DOWN SLOPE CUT OFF LEVEL
IS MINIMUM CURRENT
DOWN SLOPE CUT OFF LEVEL IS 20
OF SET VALUE
OPEN CIRCUIT VOLTAGE
IS 70 V
OPEN CIRCUIT VOLTAGE IS C.
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
J12
2T Downslope
HOT/ SOFT START TIME IN 2T
LOGIC. ADJUSTMENT RANGE
IS 0,0-9,9 SECONDS
UP SLOPE
J02
TIG ANTIFREEZE
TACK WELDING
J06
DOWN SLOPE CUT OFF
LEVEL
J07
OPEN CIRCUIT VOLTAGE
J08
“CHINA LOGIC”
TIG WELDING IN 4T
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
%
39.5 V
IN 2T THE WELDING IS ENDED DURING
DOWNSLOPE WITH A SHORT PULL ON
THE TRIGGGER
J13-15
NOT IN USE
POSITIVE START CYCLE OF
ADJUSTMENT FOR LENGTH OF
POSITIVE START CYCLE,
FACTOR 0.0 2.0
FACTORY SETTING IS 1
JO16
AC-TIG
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
X1/2
X1/3
X1/4
X1/5
X1/6
X1/7
X1/8
X1/9
X1/10
X1/11
X1/12
X1/13
X1/14
X1/15
X1/16
IDENTIFICATION OF THE SIZE OF THE MACHINE
SET VALUE FROM THE REMOTE CONTROL UNIT
SELECTION OF METHOD FROM THE REMOTE CONTROL UNIT
THERMAL PROTECTION(PTC)
NOT IN USE
CONTROL OF COOLING FANS
CONTROL OF MAINS SUPPLY VOLTAGE FROM T002 SECONDARY WINDING
NOT IN USE
WELDING CURRENT ; POSITIVE HALF-CYCLES OF DC+ OR AC
WELDING CURRENT ; NEGATIVE HALF-CYCLES OF DC- OR AC
WELDING VOLTAGE ; NEGATIVE HALF-CYCLES OF DC- OR AC
WELDING VOLTAGE ; POSITIVE HALF-CYCLES OF DC+ OR AC
CONTROL OF MAINS VOLTAGE
OVER CURRENT
SWITCH OF TIG TORCH
ADDITIONAL AC PULSE FOR TIG
X2
X2/1
X2/2
X2/3
X2/4
X2/5
X2/6
X2/7
X2/8
X2/9
X2/10
X2/11
X2/12
X2/13
X2/14
X2/15
X2/16
SOLENOID VALVE
CONTROL OF TIG SPARK
NOT IN USE
PWM POSSIBLE
CONTROL OF SECONDARY IGBT
CONTROL OF SECONDARY IGBT
+16 V
+15 V
+5 V
+5 V
GND
GND
START OF COOLING UNIT
STOP OF COOLING UNIT
NOT IN USE
NOT IN USE
TECHNICAL SERVICE MANUAL FOR MASTERTIG ACDC
TABLE 2. CONNECTOR XW101 IN MASTERTIG ACDC
PIN NUMBER
SIGNAL VALUE
DESCRIPTION
A
3.5 VAC start not active
0 V start is active
3.5 VAC start not active
0 V start is active
-
Torch start switch
B
C
D
Torch start switch
-
TABLE 3. CONNECTOR XW102 IN MASTERTIG ACDC
PIN NUMBER
SIGNAL VALUE
DESCRIPTION
A
B
30 VAC
C
30 VAC
D
E
+5 VDC
F
G
H
I
0V
0 - +5 VDC
+2 VDC=TIG
+5 VDC=MMA
-
Operating voltage for external
equipment, fuse 0.8 A
Operating voltage for external
equipment, fuse 0.8 A
Voltage reference of remote control
(upper end of the potentiometers)
GND (lower end of potentiometers)
Set value for power source
Selection of characteristic TIG/MMA curve
J
-
TABLE 4. OVER AND UNDER VOLTAGE LIMITS, (WHEN OCV)
SUPPLY VOLTAGE
LOWER LIMIT
UPPER LIMIT
165 VAC
270 VAC
175 VAC
300 VAC
340 VAC
270 VAC
460 VAC
530 VAC
365 VAC
460 VAC
MASTERTIG ACDC 1600
230 VAC
MASTERTIG ACDC 2500
230 VAC
400 VAC
460 VAC
MASTERTIG ACDC 3500
400 VAC
TECHNICAL SERVICE MANUAL FOR MASTERTIG ACDC
PICTURE 1. LEDS IN PCB A003
MASTERTIG AC/DC A003
X8
X7
T1
X5
H1
X3
T2
X1
H2
T3
V47
R77
X11
X10
R57
X4
L1
X12
LEDs, are on when machine is generating OCV
H1
H2
H1 IS ON WHEN THE MACHINE IS IN DC- TIG OR MMA
H2 IS ON WHEN THE MACHINE IS IN AC OR DC + TIG OR MMA
TECHNICAL SERVICE MANUAL FOR MASTERTIG ACDC
PICTURE 2. TRIMMERS IN PCB A002
X22
MASTERTIG AC/DC A002
X8
X1
X7
N4
N1
F2
N2
F4
X6
X5
X10
X20
X14
X2
R44
T1
R119
X3
X4
X11
TRIMMERS
R44
R118
R119
ADJUSTMENT FOR BASIC FREQUENCY
ADJUSTMENT FOR DC- MAX CURRENT
ADJUSTMENT FOR DC+ MAX CURRENT
R118
X9
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
L001
S001
G001
VG101
R001
X005
( TIG )
T001
T003
( MMA )
X004
VG201
G002
VG202
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
Order no.
4295710
4277540
4280540
4283150
9772516
9772551
4281530
4286000
9750126
4280860
3139530
4290890
4280880
3140270
9777115
9544213
4260200
9761221
2067620
9777825
2067590
9777537
9770105
9770116
4292780
9771530
9771530
4262810
9563002
9755615
4281560
4282130
4282300
3134270
4286030
9377205
9370182
2067100
2067120
4280870
2067130
3139460
4296190
2067260
2067270
3139520
3133020
4280560
3140350
9770456
9770457
9770458
9770460
9770462
9770464
Part
A002
A003
A004
C001
F001
GA001
VG101
VG102
G001
G002
VG201
G003
L001
L003
M001
R001
S001
T001
T002
T003
T004
XW101
XW102
X003
X004
X005
X006
Y001
ZC213
Z001
Z002
001
002
003
004
005
006
007
008
009
010
011
012
013
014
015
016
27.11.2001/V161601
Description
CONTROL CARD
CONTROL CARD
CONTROL CARD
CAPACITOR
FUSE 0,8A DELAYED
FUSE BOX + NUT
DIODE CARD
SPARE PART IGBT
DIODE BRIDGE
PRIMARY UNIT
SECONDARY UNIT
IGBT, SECONDARY
SECONDARY UNIT
PRIMARY CHOKE
FERRITE RING
COOLING FAN
SHUNT RESISTOR
FLIP-FLOP SWITCH
MAIN TRANSFORMER
AUXILIARY TRANSFORM.
SPARK TRANSFORMER
CURRENT TRANSFORMER
CONTROL CONNECT.
MACHINE SOCKET
CONIC COUPLING
MACHINE SOCKET
MACHINE SOCKET
FLAT CABLE
SOLENOID VALVE
CAPACITOR
FILTER CARD
MAIN CIRCUIT CARD
RUBBER
HOSE CONNECTOR
GAS CONNECTOR
HOSE CLAMP
PLASTIC HOSE
FOOT
HANDLE
HANDLE
PROTECTIVE COVER
PLASTIC PIECE
STICKER
SIDE PLATE LEFT
SIDE PLATE RIGHT
COVER
FOOT F COOL.PROFIL
FAST.PC F COOL.PROF.
CIRCUIT DIAGRAM
PLUG 2 POLES
PLUG 3-POLES
PLUG 6 POLES
PLUG 15 POLES
CONTACT , MALE
CONTACT, FEMALE
1027620 C/1916140
A002 MASTERTIG AC/DC
MAS.TIG AC/DC A003
MAS.TIG AC/DC A004
C001 AC/DC
5 X 20
AC/DC
G003 MTIG 1600 ACDC
25/15 X 10
MASTER 1500/2200
MASTER 1500/2200
WITH PILOT LAMP
1:250 PRO
4 POLES, FEMALE
R 1/4-M 8X1
50/70
50/70
L=175
470 UF
R1/8-M12
5/8 BLUE
MTIG 1600/2500 AC/DC
MTIG 1600/2500 AC/DC
MASTERTIG AC/DC
MTIG1600 ACDC
MTIG1600 ACDC
MTIG1600 ACDC
MASTERTIG 1600AC/DC
Pc.
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
0,25
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
MASTERTIG AC/DC 2000
Order no.
4295710
4277540
4280540
4283150
9772516
9772551
428086001
428600001
9750126
4299800
4300750
429089001
4280880
4281530
3149440
9777115
9544221
4260200
9760604
2067620
9777825
2067590
9777537
9770105
9770116
4292780
9771530
4262810
9563002
9755615
4281560
4282130
4282300
3134270
4286030
9377205
9370182
2067100
2067120
4280870
2067130
3139460
4296190
206726001
206727001
3139520
3133020
4280560
4280580
3149110
9770458
9770460
9770462
9770464
Part
A002
A003
A004
C001
F001
F001
G001
VG101
VG102
G002
VG201
VG201
G003
GA001
L001
L003
M001
R001
S001
T001
T002
T003
T004
XW101
XW102
X003
X004
X006
Y001
ZC213
Z001
Z002
001
002
003
004
005
006
007
008
009
010
011
012
013
014
015
016
017
13.08.2002/V162001
Description
CONTROL CARD
CONTROL CARD
CONTROL CARD
CAPACITOR
FUSE 0,8A DELAYED
FUSE BOX + NUT
PRIMARY UNIT
SPARE PART IGBT
DIODE BRIDGE
SECONDARY UNIT
IGBT, SECONDARY
IGBT, SECONDARY
SECONDARY UNIT
DIODE CARD
PRIMARY CHOKE
FERRITE RING
COOLING FAN
SHUNT RESISTOR
SWITCH
MAIN TRANSFORMER
AUXILIARY TRANSFORM.
SPARK TRANSFORMER
CURRENT TRANSFORMER
CONTROL CONNECT.
MACHINE SOCKET
CONIC COUPLING
MACHINE SOCKET
FLAT CABLE
SOLENOID VALVE
CAPACITOR
FILTER CARD
MAIN CIRCUIT CARD
RUBBER
HOSE CONNECTOR
GAS CONNECTOR
HOSE CLAMP
PLASTIC HOSE
FOOT
HANDLE
HANDLE
PROTECTIVE COVER
PLASTIC PIECE
STICKER
SIDE PLATE LEFT
SIDE PLATE RIGHT
COVER
FOOT F COOL.PROFIL
FAST.PC F COOL.PROF.
SPRING
CIRCUIT DIAGRAM
PLUG 6 POLES
PLUG 15 POLES
CONTACT , MALE
CONTACT, FEMALE
1029860
A002 MASTERTIG AC/DC
MAS.TIG AC/DC A003
MAS.TIG AC/DC A004
C001 AC/DC
5 X 20
G001 MTIG AC/DC 2000
MASTERTIG AC/DC 2000
G002 MTIG AC/DC 2000
2PCS 2X200A ACDC2000
1 PC 2X400A ACDC2000
G003 MASTERTIG AC/DC
MASTERTIG AC/DC 2000
25/15 X 10
MASTER,-TIG MLS
MASTER 1500/2200
1:250 PRO
4 POLES, FEMALE
R 1/4-M 8X1
50/70
L=175
470 UF
R1/8-M12
5/8 BLUE
MTIG 1600/2500 AC/DC
MTIG 1600/2500 AC/DC
MASTERTIG AC/DC
MASTERTIG AC/DC 2000
MASTERTIG AC/DC 2000
MTIG ACDC 1600,2000
MASTERTIG AC/DC
MASTERTIG 2000 AC/DC
Pc.
1
1
1
1
1
1
1
1
1
1
1
0
4
4
1
6
2
1
1
1
1
1
1
1
1
1
2
1
1
4
1
1
4
1
1
2
0,25
2
2
1
1
2
2
1
1
1
11
4
1
1
2
1
1
1
MASTERTIG AC/DC 2500
Order no.
4295710
4277540
4280540
4283150
9755264
9414086
9772516
9772551
4286780
9750126
9750174
2067020
3139440
4281520
4286020
4280570
3137400
9777115
9544213
4260200
976050201
2067930
9760632
9777825
2062420
9777537
9770116
9770105
4292780
9771530
4262810
9563002
4277550
4282080
4282300
3134270
9568913
9377256
9370101
2067100
2067120
4280930
2067130
3139460
4296190
4282960
2067060
2067070
2067080
3133020
4280560
3140360
9770456
9770457
9770458
9770460
9770462
9770464
Part
A002
A003
A004
C001
C003
F001
VG103
VG102
VG101
G001
G002
GA001
VG201
G003
L001
L003
M001
R001
S001
T001
S003
T002
T003
T004
XW101
XW102
X003
X004
X006
Y001
Z001
Z002
001
002
003
004
005
006
007
008
009
010
011
012
013
014
015
016
017
27.11.2001/V162501
Description
CONTROL CARD
CONTROL CARD
CONTROL CARD
CAPACITOR
CAPACITOR
BOX NUT
FUSE 0,8A DELAYED
FUSE BOX + NUT
SPARE PART IGBT
DIODE BRIDGE
RECTIFIER UNIT
PRIMARY UNIT
SECONDARY UNIT
DIODE CARD
IGBT, SECONDARY
SECONDARY UNIT
PRIMARY CHOKE
FERRITE RING
COOLING FAN
SHUNT RESISTOR
MAIN SWITCH
MAIN TRANSFORMER
V.CHANGE-OVER SW.
AUXILIARY TRANSFORM.
SPARK TRANSFORMER
CURRENT TRANSFORMER
MACHINE SOCKET
CONTROL CONNECT.
CONIC COUPLING
MACHINE SOCKET
FLAT CABLE
SOLENOID VALVE
MAIN CIRCUIT CARD
FILTER CARD
RUBBER
HOSE CONNECTOR
HOSE CONNECTOR
HOSE CLAMP
PVC HOSE
FOOT
HANDLE
HANDLE
PROTECTIVE COVER
PLASTIC PIECE
STICKER
VOLTAGE STICKER
SIDE PLATE LEFT
SIDE PLATE RIGHT
COVER
FOOT F COOL.PROFIL
FAST.PC F COOL.PROF.
CIRCUIT DIAGRAM
PLUG 2 POLES
PLUG 3-POLES
PLUG 6 POLES
PLUG 15 POLES
CONTACT , MALE
CONTACT, FEMALE
2068280 C/1916150
A002 MASTERTIG AC/DC
MAS.TIG AC/DC A003
MAS.TIG AC/DC A004
C001 AC/DC
75 UF
5 X 20
2 X 200A
MTIG2500 3J ACDC
MTIG 2500 ACDC
AC/DC
L001/MASTER2850 3J
25/15 X 10
MASTER 1500/2200
MASTER 1500/2200
K60/12 D22,5
MASTERTIG 2800/3500
1:250 PRO
4 POLES, FEMALE
R 1/4-M 8X1
50/70
L=175
MTIG AC/DC 2500
R1/8-M12
R1/8-6ML
MTIG 1600/2500 AC/DC
MTIG 2500 ACDC
MTIG 1600/2500 AC/DC
MASTERTIG AC/DC
ACDC
MTIG2500 ACDC
MTIG2500 ACDC
MTIG2500,3500W ACDC
MTIG 2500 AC/DC
Pc.
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
0,25
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
MASTERTIG 2500W ACDC
Order no.
4295710
4277540
4280540
4279500
4283150
9414086
9755264
9755223
9772516
9772551
9772520
9772551
2067020
4286780
9750126
9750174
3139440
4281520
4286020
4280570
9775731
9775729
4249080
3140840
9777115
9544213
3138320
9544306
9544305
9540415
9540411
4260200
9761375
9761323
976050201
9761622
9760632
2067930
9777825
2062420
9777537
3141530
9770116
9770105
4292780
9771530
4262810
4292790
9563002
4277550
4282080
4278020
4282300
3134270
9568911
9377256
9370101
2067100
2067120
4280930
Part
A002
A003
A004
A005
C001
C003
C003
C004
F001
F001
F002
F002
G001
VG103
VG102
VG101
G002
GA001
VG201
G003
H001
H002
K001
L001
L003
M001
M003
M003
M003
M003
M003
R001
SW301
SW302
S001
S002
S003
T001
T002
T003
T004
T005
XW101
XW102
X003
X004
X006
X007
Y001
Z001
Z002
Z004
001
002
003
004
005
006
007
008
27.11.2001/V162506
Description
CONTROL CARD
CONTROL CARD
CONTROL CARD
CONTROL CARD
CAPACITOR
BOX NUT
CAPACITOR
CAPACITOR
FUSE 0,8A DELAYED
FUSE BOX + NUT
FUSE DELAYED
FUSE BOX + NUT
PRIMARY UNIT
SPARE PART IGBT
DIODE BRIDGE
RECTIFIER UNIT
SECONDARY UNIT
DIODE CARD
IGBT, SECONDARY
SECONDARY UNIT
SIGNAL LAMP RED
SIGNAL LAMP YELLOW
REED RELAY
PRIMARY CHOKE
FERRITE RING
COOLING FAN
PUMP-MOTOR COMB.
COOLING FAN WING
COOLING FAN WING
REPAIR SET FOR PUMP
REPAIR SET FOR PUMP
SHUNT RESISTOR
LEVER SWITCH
CHANGE OVER SWITCH
MAIN SWITCH
PRESSURE SWITCH
V.CHANGE-OVER SW.
MAIN TRANSFORMER
AUXILIARY TRANSFORM.
SPARK TRANSFORMER
CURRENT TRANSFORMER
TRANSFORMER
MACHINE SOCKET
CONTROL CONNECT.
CONIC COUPLING
MACHINE SOCKET
FLAT CABLE
CURRENT/WATER CONN.
SOLENOID VALVE
MAIN CIRCUIT CARD
FILTER CARD
FILTER CARD
RUBBER
HOSE CONNECTOR
HOSE CONNECTOR
HOSE CLAMP
PVC HOSE
FOOT
HANDLE
HANDLE
2068340 D/1916160
A002 MASTERTIG AC/DC
MAS.TIG AC/DC A003
MAS.TIG AC/DC A004
A002 KWELD 4000W
C001 AC/DC
75 UF
8UF/450V AC
5 X 20
2A 5X20
MTIG2500 3J ACDC
2 X 200A
MTIG 2500 ACDC
AC/DC
25/15 X 10
MASTER 1500/2200
SIMACO
SIMACO
SPECK
SIMACO
SPECK
MASTER 1500/2200
K60/12 D22,5
MASTERTIG 2800/3500
1:250 PRO
4 POLES, FEMALE
R 1/4-M 8X1
50/70
L=175
R3/8 " /R1/4 "
MTIG AC/DC 2500
R1/8-M12
R1/8-5ML
MTIG 1600/2500 AC/DC
MTIG 2500 ACDC
Pc.
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
0,25
1
1
1
MASTERTIG 2500W ACDC
Order no.
2067130
3139460
4296190
4282950
4282960
2067060
2067070
2067080
4241513
9592126
4237831
9761302
9581005
2069370
2067360
3133020
4280560
4257910
3140360
3140370
9770456
9770457
9770458
9770460
9770462
9770464
Part
009
010
011
012
013
014
015
016
017
018
019
020
021
022
023
024
025
026
27.11.2001/V162506
Description
PROTECTIVE COVER
PLASTIC PIECE
STICKER
STICKER
VOLTAGE STICKER
SIDE PLATE LEFT
SIDE PLATE RIGHT
COVER
CONNECTION CABLE
WATER TANK
GAS HOSE
PROTECTION
HEAT EXCHANGER
SIDE PLATE LEFT
SIDE PLATE RIGHT
FOOT F COOL.PROFIL
FAST.PC F COOL.PROF.
CONIC HOSE COUPLING
CIRCUIT DIAGRAM
CIRCUIT DIAGRAM
PLUG 2 POLES
PLUG 3-POLES
PLUG 6 POLES
PLUG 15 POLES
CONTACT , MALE
CONTACT, FEMALE
2068340 D/1916160
MTIG 1600/2500 AC/DC
MASTERTIG AC/DC
GAS/WATER ACDC
ACDC
MTIG2500 ACDC
MTIG2500 ACDC
MTIG2500,3500W ACDC
D6/R1/8-1.7M
SWITCHES'LEVER
220X225 SIMACO
MTIG2500W,3500WACDC
MTIG2500W,3500WACDC
R3/8-1/2 KL
MTIG 2500 AC/DC
MTIG-W AC/DC
Pc.
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
MASTERTIG ACDC 3500W
Order no.
4295710
4277540
4280540
4279500
4283150
9755268
9755223
9772516
9772520
9772551
2067020
4286780
9750126
9750174
2069290
4288750
3142530
3142560
4281520
9755118
9753592
9753161
4268440
9775731
9775729
4249080
3137401
9777115
9777121
4288500
9544214
3138320
9544306
9544305
9540415
9540411
4260200
9761375
9761323
976050201
9761622
2069320
4288330
9777825
2062420
9777537
3143110
9770105
9770116
9771530
4219610
9771530
4262810
4292790
9563002
4288230
4288240
4282300
9480207
4282030
Part
A002
A003
A004
A005
C001
C002
C004
F001
F002
F002
G001
VG101
VG102
VG103
G002
VG201
G003
G005
GA001
C101
R101
R102
RG003
H001
H002
K001
L001
L003
L005
L006
M001
M003
M003
M003
M003
M003
R001
SW301
SW302
S001
S002
T001
RT101
T002
T003
T004
T005
XW101
XW102
X003
X004
X005
X006
X007
Y001
Z001
Z002
001
002
003
27.11.2001/V163505
Description
CONTROL CARD
CONTROL CARD
CONTROL CARD
CONTROL CARD
CAPACITOR
SMOOTHING CAPASITOR
CAPACITOR
FUSE 0,8A DELAYED
FUSE DELAYED
FUSE BOX + NUT
PRIMARY UNIT
SPARE PART IGBT
DIODE BRIDGE
RECTIFIER UNIT
SECONDARY UNIT
IGBT, SECONDARY
SECONDARY UNIT
SECONDARY UNIT
DIODE CARD
CAPACITOR
VARISTOR
RESISTOR
PTC RESISTOR
SIGNAL LAMP RED
SIGNAL LAMP YELLOW
REED RELAY
PRIMARY CHOKE
FERRITE RING
FERRITE CORE
FERRITE CHOKE
COOLING FAN
PUMP-MOTOR COMB.
COOLING FAN WING
COOLING FAN WING
REPAIR SET FOR PUMP
REPAIR SET FOR PUMP
SHUNT RESISTOR
LEVER SWITCH
CHANGE OVER SWITCH
MAIN SWITCH
PRESSURE SWITCH
MAIN TRANSFORMER
PTC RESISTOR
AUXILIARY TRANSFORM.
SPARK TRANSFORMER
CURRENT TRANSFORMER
AUXIL. TRANSFORMER
CONTROL CONNECT.
MACHINE SOCKET
MACHINE SOCKET
CONIC HOSE COUPLING
MACHINE SOCKET
FLAT CABLE
CURRENT/WATER CONN.
SOLENOID VALVE
MAIN CIRCUIT CARD
PRIMARY FILTER CARD
RUBBER
CUP SPRING
STRAINING BEAM
2069530 B/1916180
A002 MASTERTIG AC/DC
MAS.TIG AC/DC A003
MAS.TIG AC/DC A004
A002 KWELD 4000W
C001 AC/DC
25UF/700VDC
8UF/450V AC
5 X 20
2A 5X20
MTIG2500 3J ACDC
2 X 200A
MTIG 3500W ACDC
MTIG 3500W ACDC
MTIG 3500W ACDC
MTIG 3500W ACDC
4.7 NF/1000V
250V 20 MM
100R 5W
+90 C
MTIG 3500W ACDC
25/15 X 10
U57/28/16
MASTER 2800/3500
SIMACO
SIMACO
SPECK
SIMACO
SPECK
MASTER 1500/2200
K60/12 D22,5
MTIG 3500W ACDC
+140 C
MASTERTIG 2800/3500
1:250 PRO
MTIG 3500W ACDC
4 POLES, FEMALE
50/70
R1/4-6ML
50/70
L=175
R3/8 " /R1/4 "
MTIG 3500W ACDC
MTIG3500W ACDC
12.5X6.2X0.7
Pc.
1
1
1
1
1
1
1
1
2
2
1
1
1
1
1
2
2
1
8
1
1
1
3
1
1
1
1
4
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
8
32
4
MASTERTIG ACDC 3500W
Order no.
9433068
3134270
9568911
9377200
9370182
2067100
2067120
4280930
2067130
3139460
4296190
4282950
2069050
2069060
2067080
2069370
2067360
9592126
9581005
4257910
9761302
3130180
4280560
9373216
9373215
9377130
3142870
3140370
9770450
9770452
9770454
9770456
9770457
9770458
9770460
9770462
9770464
Part
004
005
005
006
007
008
009
010
011
012
013
014
015
016
017
018
019
020
021
022
023
024
025
026
027
028
27.11.2001/V163505
Description
SLOT-HEADED SCREW
HOSE CONNECTOR
HOSE CONNECTOR
HOSE CLAMP
PLASTIC HOSE
FOOT
HANDLE
HANDLE
PROTECTIVE COVER
PLASTIC PIECE
STICKER
STICKER
SIDE PLATE LEFT
SIDE PLATE RIGHT
COVER
SIDE PLATE LEFT
SIDE PLATE RIGHT
WATER TANK
HEAT EXCHANGER
CONIC HOSE COUPLING
PROTECTION
FOOT
FAST.PC F COOL.PROF.
RUBBER HOSE
RUBBER HOSE
HOSE CLAMP
CIRCUIT DIAGRAM
CIRCUIT DIAGRAM
FEMALE CONTACT BODY
FEMALE CONTACT BODY
FEMALE CONTACT BODY
PLUG 2 POLES
PLUG 3-POLES
PLUG 6 POLES
PLUG 15 POLES
CONTACT , MALE
CONTACT, FEMALE
2069530 B/1916180
M6X25
R1/8-M12
R1/8-5ML
5/8 BLUE
MTIG 1600/2500 AC/DC
MTIG 2500 ACDC
MTIG 1600/2500 AC/DC
MASTERTIG AC/DC
GAS/WATER ACDC
MTIG 3500W ACDC
MTIG 3500W ACDC
MTIG2500,3500W ACDC
MTIG2500W,3500WACDC
MTIG2500W,3500WACDC
220X225 SIMACO
R3/8-1/2 KL
SWITCHES'LEVER
T/6
13 MM
10/17 MM
13-20 MM
MTIG 3500W AC/DC
MTIG-W AC/DC
2 POLES
6 POLES
15 POLES
Pc.
8
1
1
1
0,25
4
2
1
1
3
2
1
1
1
1
1
1
1
1
1
2
11
2
2,46
0,68
8
1
1
1
3
1
1
3
8
2
25
73
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
S upply voltage
Connection power
W elding current range
Connection cable
Fuse
Loadability**
1 - 50 / 60 Hz
TIG
max.
100 %
MMA
max.
100 %
TIG
DC
AC
MMA
DC
AC
TIG AC
MMA
Fuse
Loadability***
TIG AC
MMA
30 %
100 %
20 %
100 %
ED ( T = 40 C)
ED ( T = 40 C)
ED ( T = 40 C)
ED ( T = 40 C)
50 %
100 %
60 %
100 %
ED ( T = 40 C)
ED ( T = 40 C)
ED ( T = 40 C)
ED ( T = 40 C)
OCV
DC and AC
AC Frequency
Fixed/adjustable
Efficiency
Power factor
Idling power
Temp class/degree of protection
2000
230 V +-10 %
200 A / 6,8 kVA
150 A / 4,5 kVA
160 A / 7,3 kVA
100 A / 4,2 kVA
3 A / 10 V … 200 A / 18 V
10 A / 10 V … 200 A / 18 V
10 A / 10 V … 160 A / 26,4 V
11 A / 10 V … 160 A / 26,4 V
3 x 2,5 mm2 S- 3
16 A S low
200 A / 18 V
150 A / 16 V
160 A / 26,4 V
100 A / 23,6
20 A S low
200 A / 18 V
150 A / 16 V
160 A / 26,4 V
140 A / 23,6
70 V DC
60 Hz / 50 … 200 Hz
75 % ( 160 A / 26,4 V )
0,8 ( 160 A / 26,4 V )
18 W
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
Supply voltage
Loadability
Fuse
W elding current range
OCV
AC frequency
Efficiency
Power factor
Temp class
Degree of protection
Dimensions
W eight
Coolant max. press.
Cooling unit power
3~50/60 Hz
TIG 70% ED
TIG 100% ED
MMA 40% ED
MMA 60% ED
MMA 100% ED
230 V
400 V
460 V
TIG DC
TIG AC
MMA DC
MMA AC
Fixed/adjustable
L, W, H (mm)
Kg
2500 and 2500 W
230,400,460V +/-10%
250 A / 7,5 kVA
200 A / 6,7 kVA
250 A / 10,3 kVA
200 A / 7,9 kVA
20 A Slow
16 A Slow
16 A Slow
3 A / 10 V … 250 A / 20 V
10 A / 10 V … 250 A / 20 V
10 A / 20 V … 250 A / 30 V
10 A / 20 V … 220 A / 30 V
70 V DC
60 Hz / 50 … 200 Hz
80 % ( 250 A / 30 V )
0,9 ( 250 A / 30 V )
B ( 130 C ) H ( 180 C )
IP 23 C
690 x 260 x 550, 830
39 / 65
350 kPa
1300 W
3500 W
400 V + / - 10%
350 A / 11,7 kVA
320 A / 9,3 kVA
350 A / 15,7 kVA
280 A / 11,2 kVA
20 A Slow
3 A / 10 V … 350 A / 24 V
10 A / 10 V … 350 A / 24 V
10 A / 20V … 350 A / 34 V
10 A / 20V … 350 A / 34 V
70 V DC
60 Hz / 50 … 200 Hz
80 % ( 350 A / 34 V )
0,9 ( 350 A / 34 V )
B ( 130 C ) H ( 180 C )
IP 23 C
690 x 260 x 870
74
350 kPa
1300 W
5
Switches and connectors
Main switch
Shielding gas connection
TIG-torch connection
Control cable connection, TIG-torch
Welding current connection
Return current connection
Control cable connection, remote controller
Supply cable
Mastertig 2000 AC/DC
Main switch
Shielding gas connection
Welding current connection
Control cable connection, TIG-torch
TIG-torch connection
Control cable connection, remote controller
Return current connection
Supply cable
Mastertig 2500 AC/DC
6
Switches and connectors
Main switch
Shielding gas connection
Welding current connection
Control cable connection, remote controller
Supply cable
Return current connector
TIG-torch connector
Mastertig 2500W AC/DC
Main switch
Welding current connection
Control cable connection, remote controller
Return current connector
Supply cable
Shielding gas connection
TIG-torch connector
Mastertig 3500W AC/DC
7
Switches and connectors
Pressure too low -signal lamp
Coolant overheating -signal lamp
Test switch
Torch cooling method selection
Function panels
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
2
3
4
TIG HF ignition/ contact ignition selection
AC-TIG frequency adjustment 50…200 Hz
Postgas time adjustment 0…100 s
Welding current downslope time adjustment 0…15 s.
5
6
7
Current adjustment knob/selected parameter adj
Local-/remote control selection/code lock
Pulse-TIG pulse height adjustment 3…200, 250,
350 A/pulse ratio adjustment 10…75 %
Pulse-TIG selection
Pulse-TIG background current adjustment 20…40 %/
frequency adjustment 0,1…300 Hz
Start current adjustment-70...+70 %
Minilog-function selection/adjustment -80…+20 %
Pregas time adjustment/code lock
Welding current upslope time adjustment 0…5 s.
Fusion spot welding selection/adjustment 0…10 s.
2T/4T-selection
Memory channels selection
Welding values saving into the memory channels
Memory channel selection
Broken arc welding
MMA welding dynamics adjustment
MMA welding selection
AC-TIG balance adjustment -70…+70 %
Minilog-panel
8
9
Pulsepanel
10
11
12
13
14
15
16
17
18
19
20
21
22
9
Jumper functions
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.
10
Jumper functions
Jumper
J01
Upslope
ON
Upslope angle is constant, time is dependant
on the set value.
OFF
Upslope set time remains constant, not
depending on the set value.
J02
Downslope
J03
TIG antifreeze
J04
AC balance
J05
Tacking automatics
J06
Downslope cut-off
level
J07
OCV
J08
“china logic”
Downslope angle is constanttime is
dependant on the set value.
TIG antifreeze is on.
Downslope set time remains constant, not
depending on the set value.
TIG antifreeze is not on.
Manual AC balance adjustment.
Balance automatics is on.
Tacking automatics is disabled.
Tacking automatics is enabled.
The downslope drops to minimum current
(3A DC, 10A AC).
The downslope drops to the end level,
which is 20% of the welding current.
OCV is 39V. (22V/VRD)
OCV is 70V.
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).
Inverter frequency is 18 kHz on the whole
current level.
Hot/soft–start is in use wit TIG 2T-function.
Normal 4T function.
J09
Inverter frequency
J10
2T hot/soft-start
J11
2T hot/soft–start
time adjustment
J12
2T downslope
J13
AC-welding positive
half-cycle
J14
Start switch short
press
J15
AC-TIG start cycle
J16
AC-TIG start cycle
length
J17
MMA ignition pulse
J18
J19
Inverter frequency is 18kHz/36kHz on
MMA.
Hot/soft–start is not in use with TIG 2Tfunction.
Hot/soft–start time with 2T-function.
Adjustment range is 0,0- 9,9 s.
On 2T the downslope is not cut-off by a
short (nor long) press on the switch.
On AC-TIG the height of the pos. half-cycle
is the same as the negative half-cycle´s
height.
Torch switch short press time limit is 0,3 s.
On 2T the welding is stopped by a short
pres on the switch during the downslope.
On AC-TIG the height of the pos. halfcycle depends on the set value and balance
adjustments.
Torch switch short press time limit is 0,7 s.
AC-TIG-welding is started with a negative
half-cycle.
Length adjustment for the DC start of the
positive half cycle in AC-TIG 0.0 .... 2.0.
AC-TIG-welding is started with a positive
half-cycle.
Factory setting is 1.
MMA ignition pulse height adjustment 0.0
..... 2.0.
-
Factory setting is 1.
-
11
Error codes
Err1
Uin Err
Power source secondary voltage is & gt; + 90 V for overi 4 seconds.i
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, minilogpanel 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
C2
V2
UG2
C3
U1
V3
U1
UG3
UG3
t
t
t
T001
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
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.
R001
T003
TIG
T001
V5
UG5
V4
V6
When the current type is DC+, is IGBT V5 conductive.
R001
T003
TIG
T001
V5
V4
V6
UG6
When current type is DC-, is IGBT V6 conductive.
13
Operation principle
R001
T003
TIG
T001
V5
UG5
V4
V6
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
EMI-filt.
Primary
rectifying
Cooling unit
control card
A005
Spark transformer
Filtering
Primary
inverter
Main
Sec.
Sec.
transformer rectifying inverter
Primary inverter
control card
A002
Sec. Inverter
Control card
A003
Spark card
A004
M
P
P001
14
To the primary rectifier
Filter cards
GND
+ 15 V
Control
Information of overvoltage to
control cards A002 and A001
Mastertig 2000 AC/DC Z001
L1
L1
L2
L3
To primary rectifier
DC link +
DC link L3
+ 15 V
Overvoltage watch
GND
Protection circuits against wrong supply voltage
Mastertig 2500 AC/DC Z002
15
Filter cards
Intermediate circuit DC To the primary rectifier L1, L2, L3
+ 15 V
Watch
GND
Aux. Transformer T002
primary 400 Vac
L1, L2
Information of overvoltage to
control cards A002 and A001
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.
Filter card layout
X6
X7
X1
X8
X5
X2
X4
X3
Mastertig 2000 AC/DC Z001
16
Filter card layout
X3
X1
X15
X7
X9
X11
X5
X13
X19
R3
X24
X25
X16
X22
X18 X23
Mastertig 2500 AC/DC Z002
X19
X2 X15 X21
X9
X8
X6
X7
X1
X20
X4
X5
X11
X10
X14
Mastertig 3500 AC/DC Z002
X22
X16
X17
X18
X12
X13
17
Main circuit cards
Mastertig 2000 AC/DC Z002
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 2500 AC/DC Z001
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.
18
Main circuit cards
Mastertig 3500 AC/DC Z001
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.
Main circuit cards layout
X1
X6
X4
X3
X2
Mastertig 2000 AC/DC Z002
X5
19
Main circuit cards layout
X8
X6
X7
X9
X2
X1
X3
X5
X4
Mastertig 2500 AC/DC Z001
3/E1
X5
X8
X9 X9 X10
X7 X7
X5
X5
X4
Mastertig 3500 AC/DC Z001
20
Voltage selector switch
Mastertig 2500 AC/DC S003
Voltage selector switch S003 is used to select the correct net voltage (3~ 230, 400, 460 Vac). It
sets the correct transformation ratios for the main transformer T001 and voltages for auxiliary
transformer T002.
Secondary circuit components
Mastertig AC/DCs
Diode cards rectify the main transformer T001´s secondary voltages. The secondary unit
G002´s IGBT-transistors genereate the current type: DC-, DC+ or AC. Control card A003
generates the auxiliary pulse (approx. 400V/ 1ms) needed in AC welding.
21
Secondary circuit components
Mastertig AC/DCs
The shunt resistor R001 is used to measure secondary circuit current. The spark transformer
T003 increases the TIG ignition spark to approx. 10 kV. C001 gives protection against the
TIG ignition spark.
Mastertig 2500W/3500W AC/DC
Reed-relay K001 protects the liquid cooled TIG-torch, in case the cooling method selector switch
is in gas-position.
22
Diode card layout
Cooling unit
Mastertig 2500W AC/DC
The auxiliary transformer T005 generates the 230 Vac supply voltage for the pump motor.
The filter card Z004´s PTC-resistors protect the auxiliary transformer T005, if a wrong supply
voltage is selected by the voltage selector switch S003.
Mastertig 3500W AC/DC
The auxiliary transformer T005 generates the 230 Vac supply voltage for the pump motor.
23
Filter card Z004 layout
X6
X3
X4
X13
X12
X11
X5
X2
X1
Mastertig 2500W AC/DC Z004
Cooling unit control card A005
Coolant temperature-PTC RW301
Pump motor control relay K1
Pressure watch S002
Too low pressure-warning
lamp
Coolant overheat
warning lamp
Power supply from control card A002
Control
Test switch
Liquid-/gas cooling
selection switch
Cooling unit start
To Reed-relay K001
GND
Mastertig 2500W/3500W AC/DC A005
24
Control card A005 layout
X1
K1
X2
Control card A001 (panel) functions
Control cardA001 includes the following functional blocks:
• Processor
• Memories
• Displays
• Panel membrane switches read
• Potentiometers
• Net voltage watch
• Fan control
• Cooling unit control/watch
• Secondary IGBT control
• TIG ignition spark control
• Solenoid valve control
• AC-TIG auxiliary pulse control
• Temperature watch
• Machine size detection
• Torch switch start
• Remote controller set value
• Secondary current and voltage watch
25
Control card A001 connectors
X1/1
X1/2
X1/3
X1/4
X1/5
X1/6
X1/7
X1/8
X1/9
X1/10
X1/11
X1/12
X1/13
X1/14
X1/15
X1/16
X2/1
X2/2
X2/3
X2/4
X2/5
X2/6
X2/7
X2/8
X2/9
X2/10
X2/11
X2/12
X2/13
X2/14
X2/15
X2/16
Machine size detection (1600/2500)
Set value from the remote controller
Process selecting from the remote controller
Overheat protections (PTC)
Machine size detection (2000)
Fan control
Net voltage watch from the aux. Transformer T002 secondary
Welding current; DC+ or AC positive half cycles
Welding current; DC- or AC negative half cycles
Welding voltage; DC+ or AC positive half cycles
Welding voltage; DC- or AC negative half cycles
Net overvoltage watch
Control amplifier (N6-A) output
TIG-torch switch
AC TIG auxiliary pulse control
Solenoid valve
TIG ignition spark control
Set value from A001
PWM enable
Secondary IGBT control
Secondary IGBT control
+ 16 V
+ 16 V
+5V
+5V
GND
GND
Cooling unit start
Stop-command from the cooling unit
Inverter frequency 18/36 kHz
Machine size detection (3500)
26
Control card A002 functions / connectors
Control card A002´s functional blocks:
• PWM-development
• Primary IGBT control
• Current and voltage adjustment loop
• Aux. Voltages development + 5, ± 15, + 16 and + 24 V
• Secondary overvoltage watch
• Primary current limiting circuit
• Net overvoltage and undervoltage watch
• Fan control power stage
• Solenoid valve control power stage
• Cooling unit control power supply
X1/1
X1/2
X1/3
X1/4
X1/5
X1/6
X1/7
X1/8
X1/9
X1/10
X1/11
X1/12
X1/13
X1/14
X1/15
X1/16
Machine size detection (1600/2500)
Set value from the remote controller
Process selecting from the remote controller
Overheat protections (PTC)
Machine size detection (2000)
Fan control
Net voltage watch from the aux. Transformer T002 secondary
Welding current; DC+ or AC positive half cycles
Welding current; DC- or AC negative half cycles
Welding voltage; DC+ or AC positive half cycles
Welding voltage; DC- or AC negative half cycles
Net overvoltage watch
Control amplifier (N6-A) output
TIG-torch switch
AC TIG auxiliary pulse control
X2/1
X2/2
X2/3
X2/4
X2/5
X2/6
X2/7
X2/8
X2/9
X2/10
X2/11
X2/12
X2/13
X2/14
X2/15
X2/16
Solenoid valve
TIG ignition spark control
Set value from A001
PWM enable
Secondary IGBT control
Secondary IGBT control
+ 16 V
+ 16 V
+5V
+5V
GND
GND
Cooling unit start
Stop-command from the cooling unit
Inverter frequency 18/36 kHz
Machine size detection (3500)
27
Control card A002 connectors
X3/1-2
X4/1-2
X5
X6
X7
X8/1
X8/2
X8/3
X8/4
X8/5
X9/1-2
X9/3-4
X9/5
X9/6-7
X9/8-9
X9/10
X9/12-13
X9/14
X9/15
Primary IGBT control
Primary IGBT control
Aux. Transformer T002 0V
Aux. Transformer T002 13 Vac
Aux. Transformer T002 13 Vac
TIG ignition spark control
13 Vac
TIG-torch start detection
+ 24 V
GND
Solenoid valve
Fan
Secondary voltage (U2)
Fan
Shunt resistor R001
Machine size (3500)
Current transformer T004
GND
Machine size (1600/2500)
X10/1
X10/2
X10/3
X10/4
X10/5
X10/6
X10/7
X10/8
X10/9
X10/10
X10/11
X10/12
X10/13
X10/14
X10/15
X10/16
Secondary IGBT control
+5V
Secondary IGBT control
- 15 V
+ 15 V
GND
Set value from remote controller
TIG/MMA selection from remote controller
AC-TIG auxiliary pulse control
+ 24 V
+ 15 V
+ 15 V
GND
GND
-
X11/1
X11/2
X11/3
X11/4
X14/1-6
X20/2
X20/3
X20/4
X22
Stop-command from the cooling unit
Cooling unit control
+ 24 V
GND
PTC-resistors
Net overvoltage
+ 15 V
GND
Protective earth
28
Control card A002 layout
3,15 AT
X8
X22
X7
X1
X6
X5
X10
X20
R44
Inverter frequency
X2
X14
R119
Max current DC+
X9
R118
Max current DCX11
X3
X4
X8
X22
X7
X1
X10
X6
X5
X20
X2
R44
Inverter frequency
X14
X9
X3
X4
From serial number 985660/L onwards
R118
Max current
X11
29
Control card A003 functions / connectors
Control card A003´s functional blocks:
• Secondary IGBT control power stage
• Remote controller connection
• AC-TIG aux. Pulse developement
• OCV circuit
X1/1
X1/2
X1/3
X1/4
X1/5
X1/6
X1/7
X1/8
X1/9
X1/10
X1/11
X1/12
X1/13
X1/14
X1/15
X1/16
Secondary IGBT control
+5V
Secondary IGBT control
- 15 V
+ 15 V
GND
Remote controller set value
TIG/MMA selection from remote controller
AC-TIG aux. Pulse control
+ 24 V
+ 15 V
+ 15 V
GND
GND
-
X2
X3/1,4
X3/3,6
X4
X5/1,3
X5/3,5
X7
X8/1
X8/2
X8/3
X8/4
X10
X11
X12
AC-TIG aux. Pulse power supply (auxiliary coil)
Secondary IGBT control
Secondary IGBT control
AC-TIG aux. Pulse power supply (auxiliary coil)
Secondary IGBT control
Secondary IGBT control
Protective earth
TIG/MMA selection from remote controller
Remote controller potentiometer voltage reference
Remote controller potentiometer " slide "
Remote controller potentiometer ground
AC-TIG aux. Pulse / OCV circuit DC +
OCV circuit DC Main transformer secondary mid-points
30
Control card A003 layout
X8
X7
X5
H1 (DC-)
H2 (DC+/AC)
X3
X1
X11
X4
X2
X12
L1
X8
X3
X5
X7
H1 (DC-)
L1
H2 (DC+/AC)
X1
X11
X4
X2
X12
From serial number 980039/L onwards
31
Control card A004 functions / connectors
Control card A004 includes these operational blocks:
• TIG ignition spark development
• TIG-torch start detection
X1/1,3
X2/1,3
X3/2
X3/3
X3/4
X3/5
X3/6
X4/1,2
Spark transformer primary (approx. 1 kV)
360 Vac from aux. Transformer T002
TIG-torch start detection
13 Vac
+ 24 V
TIG ignition spark control
GND
TIG-torch start switch
Control card A004 layout
X4
X3
X2
X1
32
Structure
A003
T002
S001
A002
Z001
A001
VG102
M001, M002
T001
L1
GA001
T003
Y001
A004
R001
VG101
VG201, VG202
Z002
Mastertig 2000 AC/DC
33
Structure
A003
S001
A002
Z002
A001
T002
VG101
VG201, VG202
Z001
GA001
C003
L1
T001
T005
S002
Z004
T003
A004
K001
S003
VG103
M001, M002
T004
A005
M003
Mastertig 2500W AC/DC
34
Structure
A003
S001
A002
Z002
T002
A001
Y001
VG101
GA001
Z001
M001
L1
T001
C002
S002
T003
K001
A004
VG103
T004
G002
T005
A005
M003
Mastertig 3500W AC/DC
35
Troubleshooting
The machine may be repaired only by a workshop/technician licensed and authorized for the
job!
First do a visual check to find possible damage points, for example loose connectors broken wires
or signs of overheating.
Troubleshooting diagram
PROBLEM
POSSIBLE CAUSE
REMEDY
The power source doesn´t start.
Net fuse / fuses have burnt.
Check net fuses.
Panel lights and displays remain blank.
A damaged supply cable.
Check the supply phases from connector
X001. Fix/replace the supply cable as
needed.
Check the main switch condition..
A faulty main switch S001.
A faulty auxiliary transformer T002 or a
bad connection in auxiliary transformer
connectors.
Check the auxiliary transformer T002
and the connectors. Fix bad connections
or replace T002 if necessary.
Check the control card A002 fuses.
Replace the A002 if necessary.
A faulty control card A002.
After startup the fans remain rotating.
Panel not operating.
Bad contact in the flat cable between
function panel and control card A002.
Not all functions of the panel working
correctly.
Faulty panel.
The power source won´t start up.
Wrong supply voltage, over or under
voltage signal lamp is on.
Check flat cables and connectors X1 and
X2.
NOTE! RESET THE PANEL, BY
PRESSING DOWN CONTACT-TIG
AND HF-TIG BUTTONS, WHILE
STARTING UP THE POWER
SOURCE BY MAIN SWITCH..
Wrong supply voltage has been
selected(ACDC 2500). A phase is
missing.
Uin Err error message is shown on the
display.
IF SOME PANEL FUNCTION IS NOT
WORKING AFTER RESETTING THE
PANEL, REPLACE THE PANEL
MEMBRANE OR THE PANEL.
Disconnect the power source plug from
the net, and select the correct supply
voltage by selector switch S003 (ACDC
2500 and 2500W). Check the presence
of all supply phases.
Err 1 error message is shown on the
display.
Power sources output voltage has risen
over 90 V for more than 4 seconds.
Check the condition of the control card
A003.
The net fuse gets burnt during startup.
A faulty supply cable.
Check and replace the supply cable as
necessary.
A faulty primary circuit component.
Check the primary side components
(main switch, primary rectifier, primary
IGBT etc.).
A faulty secondary circuit component.
Check the diode cards, secondary IGBT
and control card A003).
36
Troubleshooting diagram
PROBLEM
POSSIBLE CAUSE
REMEDY
Check / replace the fuse as necessary.
Faulty aux. Transformer T005.
Check the aux. Transformer T005
primary and secondary voltages. Check
the filter card Z004 (2500W).
Check the control card A005.
Coolant level too low.
Check the coolant level.
A faulty pressure switch S002.
Check the voltage over the pressure
switch from control card A005 between
X2/1 and X2/8; Pressure = 0V, no
pressure = 24V.
Pressure switch limit (approx.1bar.)
incompatible with the torch.
The missing coolant pressure warning
lamp H001 is on..
Fuse F002, 2A has burnt.
Faulty control card A005.
The cooling unit doesn´t work.
The cooling unit doesn´t start by the test
switch.
Re-adjust the pressure switch limit:
1. Run the pump with the test switch
SW301 during adjustment.
2. After 5 seconds turn the adjustment
screw carefully, until the lamp H001
goes off.
3. Check the result by welding.
Pump motor start capacitor C004 faulty.
Check / replace capacitor.
A faulty control card A005.
Check / replace the A005.
The system has an air bubble blocking
the circulation. Coolant level too low.
Check the coolant level in the reservoir.
Hint: Blow compressed air into the
reservoir. The filler neck can be block
by hand.
The coolant will not circulate by the test
switch SW301.
The coolant doesn´t return to the
reservoir.
TIG HF-ignition doesn´t work.
A leak in the system.
Check all hoses and connections in the
system.
A faulty TIG -torch.
Check and fix the TIG-torch
(consumable parts / electrode).
A faulty auxiliary transformer T002.
Check the aux. Transformer T002
secondary voltages from control card
A004´s connectors X2/1=0V and
X2/3=360V. Replace T002 as
necessary.
A faulty control card A004.
Check the spark on / off -control from
control card A004 connector X3/5.
AC TIG-welding doesn´t work. Th e arc
dies after a short period of welding.
A faulty control card A003.
Check / replace control card A003.
In AC-welding the second half-cycle is
missing. DC+ or DC- method is
inoperative.
A faulty control card A003.
Check if the process is changed on
control card A003. Replace the card as
necessary.
A faulty secondary unit; IGBT or diode
cards.
Check / replace secondary unit faulty
components.
37
Net voltage operational limits
Mastertig 2000
230 Vac
Minimum
165 Vac
Maximum
270 Vac
Mastertig 2500
230 Vac
400 Vac
460 Vac
Minimum
175 Vac
300 Vac
340 Vac
Maximum
270 Vac
460 Vac
530 Vac
Mastertig 3500
400 Vac
Minimum
365 Vac
Maximum
460 Vac
Signals between control card A001 (panel) and A002, X1 and X2
Set value from remote controller, voltage on connector X1/2
No remote controller
Remote controller minimum
Remote controller maximum
38
Process selection from the remote controller, voltage on connector X1/3
TIG-process
MMA process
Temperature watch, voltage on connector X1/4
Temperature watch in room temperature (approx.. + 20º C)
Fan control, voltage on connector X1/6
Fans on
Info of welding current (DC+ and AC pos. half-cycles), voltage on X1/9
DC+ 10 A, MMA
DC+ 200 A, MMA
DC+ 350 A, MMA
39
Info of welding current (DC+ and AC pos. half-cycles), voltage on X1/9
AC 10 A, MMA
AC 200 A, MMA
AC 350 A, MMA
Info of welding current (DC+ and AC pos. half-cycles), voltage on X1/11
+ 15 V, MMA
15 Vac, MMA
+ 30 V, MMA
+ 70 V, MMA
30 Vac, MMA
Net overvoltage watch, voltage on connector X1/13
Net voltage OK
Net overvoltage
40
Torch start switch detection, voltage on connector X1/15
Torch start switch open
Torch start switch closed
41
AC TIG-welding auxiliary pulse control, voltage on connector X1/16
AC TIG-welding auxiliary pulse control
AC TIG-welding auxiliary pulse control
42
Solenoid valve Y001 control, voltage on connector X2/1
Solenoid valve open
TIG HF-ignition spark control, voltage on connector X2/2
TIG ignition spark control (if the arc is not on immediately, then controls will be on in 10 ms. Intervals for 2 seconds)
Set value from control card A001 (panel), voltage on connector X2/3
10 A
100 A
200 A
350 A
43
PWM-control enabling, voltage on connector X2/4
PWM enabled
PWM disabled
Secondary IGBT control, voltage on connector X2/5
DC+
DC-
AC 50 Hz, MMA
AC 200 Hz, TIG
44
Secondary IGBT control, voltage on connector X2/5
Balance -70, TIG
Balance +70, TIG
Cooling unit control, voltage on connector X2/13
Cooling unit is off
Cooling unit is on
45
Cooling unit monitorings, voltage on connector X2/14
Cooling OK
Error, stop -command to cooling unit
Inverter frequency selection, voltage on connector X2/15
36 kHZ
18 kHZ
Measurings from control card A002 connector X8
46
TIG ignition spark control, voltage on connector X8/1
TIG ignition spark control (if the arc is not on immediately, then the controls are on in 10 ms. Intervals for 2 s.)
Torch start switch detection, voltage on connector X8/3
Torch start switch open
Torch start switch closed
47
Measurings from control card A002 connector X9
Solenoid valve Y001 control, voltage on connector X9/1-2
Solenoid valve open
Fan control, voltage on connector X9/3-4, 6-7
Fan on
Fan ”soft start”
48
Information of secondary side voltage, voltage on connector X9/5
Idling DC+, MMA
Information of primary side current, voltage on connector X9/12-13
100 A
200 A
350 A
49
Measurings from control card A002 connector X10
Secondary IGBT control, voltage on connector X10/1
DC+
DC-
AC 50 Hz, MMA
AC, MMA / Idling
AC 200 Hz, TIG
50
Secondary IGBT control, voltage on connector X10/1
Balance -70, TIG
Balance +70, TIG
Set value from remote controller, voltage on connector X10/7
Without controller
Minimum
Maximum
Process selection from remote controller, voltage on connector X10/9
MMA
TIG
51
AC TIG auxiliary pulse control, voltage on connector X10/10
AC-TIG auxiliary pulse control
Measurings from control card A002 connector X11
Cooling unit monitorings, voltage on connector X11/1
Cooling OK
Error, stop -command to power source
52
Cooling unit control, voltage on connector X11/2
Cooling unit is not on
Cooling unit is on
Measurings from control card A002 connector X20
Net overvoltage measuring, voltage on connector X20/2
Net voltage OK
Net overvoltage, stop -command to power source
53
Measurings from control card A003 connector X3
Secondary IGBT control, voltage on connector X3/1-4
DC+
DC-
AC, MMA / idling
AC 50 Hz, MMA
54
Secondary IGBT control, voltage on connector X3/1-4
AC 200 Hz, TIG
Balance -70, TIG
Balance +70, TIG
55
Measurings from control card A003 connector X8
Remote controller voltage reference, voltage on connector X8/2-4
Set value from remote controller, voltage on connector X8/3-4
Min
Max
56
Process selection from remote controller, voltage on connector X8/1-4
MMA
TIG
Mastertig 2000 AC/DC inverter controls
IGBT gate pulses, voltage on connector X3/1-2 (A002)
Mastertig 2000 AC/DC
IGBT gate pulse control on MMA / idling
57
IGBT gate pulses, voltage on connector X3/1-2 (A002)
Mastertig 2000 AC/DC
IGBT gate pulse control 10 A
Mastertig 2000 AC/DC
IGBT gate pulse control 50 A
58
IGBT gate pulses, voltage on connector X3/1-2 (A002)
Mastertig 2000 AC/DC
IGBT gate control 100 A
Mastertig 2000 AC/DC
IGBT gate control 106 A (Note! Frequency!)
59
IGBT gate pulses, voltage on connector X3/1-2 (A002)
Mastertig 2000 AC/DC
IGBT gate control 160 A
Main transformer T001 primary voltage
Mastertig 2000 AC/DC
60
T001 primary voltage 10 A
Main transformer T001 primary voltage
Mastertig 2000 AC/DC
T001 primary voltage 50 A
Mastertig 2000 AC/DC
T001 primary voltage 100 A
61
Main transformer T001 primary voltage
Mastertig 2000 AC/DC
T001 primary voltage 106 A (Note! Frequency!)
Mastertig 2000 AC/DC
T001 primary voltage 160 A
62
Voltage after the diode cards
Mastertig 2000 AC/DC
After the diode card 10 A
Mastertig 2000 AC/DC
After the diode card 50 A
63
Voltage after the diode card
Mastertig 2000 AC/DC
After the diode card 100 A
Mastertig 2000 AC/DC
After the diode card 106 A (Note! Frequency!)
64
Voltage after the diode cards
Mastertig 2000 AC/DC
After the diode card 160 A
Secondary voltage U2 using a low-pass filter
10 kΩ
TIG
22 nF
U2
65
Secondary voltage U2 using a low-pass filter
Mastertig 2000 AC/DC
AC 10 A 50 Hz,MMA
Mastertig 2000 AC/DC
AC 100 A 50 HZ, MMA
66
Secondary voltage U2 using a low-pass filter
Mastertig 2000 AC/DC
AC 160 A 50 Hz, MMA
Mastertig 2000 AC/DC
AC 10 A 100 Hz, TIG (Balance 50/50, balance automatics ON)
67
Secondary voltage U2 using a low-pass filter
Mastertig 2000 AC/DC
AC 50 A 100 Hz, TIG
Mastertig 2000 AC/DC
AC 100 A 100 Hz, TIG
68
Secondary voltage U2 using a low-pass filter
Mastertig 2000 AC/DC
AC 160 A 100 Hz, TIG
Mastertig 2000 AC/DC
AC 200 A 100 Hz, TIG
69
Mastertig 2500 AC/DC inverter controls
IGBT gate pulses, voltage on connector X3/1-2 (A002)
Mastertig 2500 AC/DC
IGBT gate control 10 A
Mastertig 2500 AC/DC
IGBT gate control 100 A
70
IGBT gate pulses, voltage on connector X3/1-2 (A002)
Mastertig 2500 AC/DC
IGBT gate control 106 A (Note! Frequency!)
Mastertig 2500 AC/DC
IGBT gate control 250 A
71
Voltage over a lower IGBT
Mastertig 2500 AC/DC
Voltage over the lower IGBT 10 A
Mastertig 2500 AC/DC
Voltage over the lower IGBT 100 A
72
Voltage over the lower IGBT
Mastertig 2500 AC/DC
Voltage over the lower IGBT 250 A
Secondary voltage U2 using a low-pass filter
10 kΩ
TIG
22 nF
U2
73
Secondary voltage U2 using a low-pass filter
Mastertig 2500 AC/DC
AC 10 A 50 Hz, MMA
Mastertig 2500 AC/DC
AC 100 A 50 Hz,MMA
74
Secondary voltage U2 using a low-pass filter
Mastertig 2500 AC/DC
AC 250 A 50 Hz, MMA
Mastertig 2500 AC/DC
AC 10 A 100 Hz, TIG (Balance 50/50, balance automatics ON)
75
Secondary voltage U2 using a low-pass filter
Mastertig 2500 AC/DC
AC 100 A 100 Hz, TIG
Mastertig 2500 AC/DC
AC 250 A 100 Hz, TIG
76
Mastertig 3500 AC/DC inverter controls
IGBT gate pulses, voltage on connector X3/1-2 (A002)
Mastertig 3500 AC/DC
IGBT gate control on idle
Mastertig 3500 AC/DC
77
IGBT gate control 10 A
IGBT gate pulses, voltage on connector X3/1-2 (A002)
Mastertig 3500 AC/DC
IGBT gate control 100 A
Mastertig 3500 AC/DC
IGBT gate control 106 A
78
IGBT gate pulses, voltage on connector X3/1-2 (A002)
Mastertig 3500 AC/DC
IGBT gate control 200 A
Mastertig 3500 AC/DC
IGBT gate control 350 A
79
Secondary voltage U2 using a low-pass filter
Mastertig 3500 AC/DC
AC 10 A 50 Hz, MMA
Mastertig 3500 AC/DC
AC 100 A 50 Hz, MMA
80
Secondary voltage U2 using a low-pass filter
Mastertig 3500 AC/DC
AC 200 A 50 Hz, MMA
Mastertig 3500 AC/DC
AC 350 A 50 Hz, MMA
81
Secondary voltage U2 using a low-pass filter
Mastertig 3500 AC/DC
AC 50 A 100 Hz, TIG (Balance 50/50, balance automatics ON)
Mastertig 3500 AC/DC
AC 100 A 100 Hz, TIG
82
Secondary voltage U2 using a low-pass filter
Mastertig 3500 AC/DC
AC 200 A 100 Hz, TIG
Mastertig 3500 AC/DC
AC 350 A 100 Hz, TIG
83