Kemppi MasterTig 3500 Bedienungsanleitung

Service manual

Ver. 1.0

1400

1500

2200

2800

3500

1500

2200

2800

3500

Contents

General 3

Technical data, switches and connectors 3-6

Mastertig function panels 7-10

Operating principle 11

IGBT gate pulse (2800/3500) 12

Voltage over the lower IGBT (2800/3500) 13

Voltage after the secondary diodes (2800/3500) 14

IGBTgate pulse (1400-2200) 15

Voltage over the lower IGBT (1400-2200) 16

Voltage after the secondary diodes (1400-2200) 17

Troubleshooting 18-20

Power source control card A001 block diagram 21

Mastertig-power source´s TIG-section´s functions 22

Signals between control cards A001 and A002 23

Signals between control cards A002 and A004 23

Control card A001 layout (1400/1500) 24

Control card A001 layout (2000/2200) 24

Control card A001 layout (2800/3500) 25

MSD 1-meter unit layout 25

Control card A002 layout (1500/2200) 26

Control card A002 layout (2800/3500) 26

Control card A004 layout (2800/3500) 27

Control card A001 operation check 27

Control card A002 operation check 28-29

Control card A004 operation check 30

Notes 31

Master- and Mastertig-power sources are MMA and TIG power sources designed for

demanding professional use.

Master- and Mastertig-power sources are IGBT-inverters, controlled by PWM-principle.

Operation frequency is approx. 18 kHz.

5 power source sizes are available; 1~ 140 A, 1~ 150 A, 3~ 220 A, 3~ 280 A and 3~ 350 A

General

Technical data, switches and connectors

1 Main switch S001 and welding current connectors

2 Overheat protection signal lamp

3 Current adj. potentiometer

Master 1400

Supply voltage 1∼,50/60 Hz

Connection power 20% ED

60% ED

100% ED

Supply cable/ fuses

220V –10%….240V +6%

140 A/ 6,2 kVA

105 A/ 4,4 kVA

75 A/ 2,9 kVA

3 x 1,5S / 16 A slow

Welding current range MMA

Suitable electrode sizes

Welding power adj.

15 A / 20,0 V..140 A / 25,6 V

∅1,5…..3,25 mm

stepless

OCV

Efficiency

Idling power

Approx. 80 V

80% (140 A / 25,6V)

Approx. 10 W

Degree of protection / Casing

class

IP 23

Weight 10 kg

Master 1500

1 Main switch S001, welding current connectors and

dynamics adjustment

2 Overheat protection signal lamp

3 Remote controller connection

4 Local / remote control

5 Current adjustment potentiometer

Supply voltage 1∼,50/60 Hz

Connection power 20% ED

60% ED

100% ED

Supply cable/ fuses

220V –10%….240V +6%

150 A / 6,6 kVA

105 A / 4,4 kVA

75 A / 3,0 kVA

3 x 1,5S / 16 A slow

Welding current range MMA

(TIG

Suitable electrode sizes

Welding power adjustment

15 A / 20,5 V..150 A / 26,0 V

5 A / 10,2 V..150 A / 16,0 V)

∅1,5…..3,25 mm

stepless

OCV

Efficiency

Idling power

Approx. 80 V

80% (150 A / 26,0 V)

Approx. 10 W

Degree of protection / Casing

class

IP 23C

Weight 10,5 kg (TIG, 13,5 kg)

Auxiliary devices Remote controllers

C 100C, C 100D

Master 2200

1 Main switch S001, welding current connections and

dynamics adjustment

2 I/0-signal lamp

3 Remote controller connecyor

4 Overheat protection signal lamp

5 Remote / local control selection

6 Current adjustment potentiometer

Supply voltage 3∼,50/60 Hz

Connection power 25% ED

60% ED

100% ED

Supply cable / fuses

380V –10%….415V +6%

220 A / 8,4 kVA

145 A / 5,5 kVA

110 A / 3,5 kVA

4 x 1,5S / 10 A slow

Welding current range MMA

(TIG

Suitable electrode sizes

Welding power adjustment

15 A / 20,5 V…220 A / 28,8 V

5 A / 10,2 V…220 A / 18,8)

∅1,5…4,0 (5,0) mm

stepless

OCV

Efficiency

Idling power

Approx. 80 V

82% (220 A / 28,8V)

Approx. 10 W

Degree of protection / Casing

class

IP 23C

Weight 12,5 kg (TIG, 16 kg)

Auxiliary devices Remote controllers

C 100C, C 100D

Master 2800 and 3500

1 Main switch S001 and welding current connectors

2 I/0-signal lamp

3 Overheat protection signal lamp

4 Dynamics adjustment

5 Current adjustment potentiometer

6 local / remote control

7 Remote controller connector

1234

Supply voltage 3∼,50/60 Hz

Connection power 35% ED

60% ED

100% ED

Supply cable/ fuses

380V –10%….415V +6%

280 A / 11,5 kVA

213 A / 8,5 kVA

165 A / 6,0 kVA

4 x 1,5S / 10 A slow

380V –10%….415V +6%

350 A / 15,0 kVA

267 A / 11,0 kVA

207 A / 8,0 kVA

4 x 2,5S / 16 A slow

Welding current range MMA

(TIG

Suitable electrode sizes

Welding power adjustment

15 A / 20,5 V…280 A / 31,2 V

5 A / 10,2 V…280 A / 21,2 V)

∅1,5…n. 5,0 mm

stepless

15 A / 20,5 V…350 A / 34,0 V

5 A / 10,2 V…350 A / 24,0 V)

∅1,5…n. 6,0 mm

stepless

OCV

Efficiency

Idling power

Approx. 75 V

83% (280 A/ 31,2 V)

approx. 25 W

approx. 75 V

83% (350 A/ 34,0 V)

approx. 25 W

Degree of protection / Casing

class

IP 23 IP 23

Weight 22 kg (TIG, 27 kg) 25 kg (TIG, 30 kg)

Auxiliary devices Remote controllers

C 100C, C 100D, C100T,

MSD 1

Remote controllers

C 100C, C 100D, C100T,

MSD 1

Mastertig 1500 and 2200

1 Main switch S001, dynamics adjustment and welding

current connections

2 Current adjustment potentiometer

3 Overheat protection signal lamp

4 Local / remote control selection

5 Remote controller connector

2345

Pregas time Pause current Postgas time

2T/4T-selection

Ignition method and process selection

Downslope timePulse frequencyContinous / pulse

welding selection,

pulse ratio

adjustment

Pulse panel

Minilog-panel

Pause current Post gas time

2T/4T-selection

Ignition method and process selection

Downslope time

Pulse frequency

Minilog-operation selection,

minilog-current adjustment

Minilog-functions not in use

Current upslope time,

continous welding

Continous welding selection

Pulse welding selection and

pulse ratio adjustment

Mastertig 2800 and 3500

234

1 Main switch S001 and welding current connectors

2 I/0-signal lamp

3 Overheat protection signal lamp

4 Dynamics adjustment

5 Current adjustment potentiometer

6 Local / remote control selection

7 Remote controller connector

Pregas time Pause current Postgas time

2T/4T-selection

Ignition method and process

selection

DownslopePulse frequencyContinous / pulse

welding selection,

pulse ratio

adjustment

Pulse panel

Minilog-panel

Pause current Postgas time

2T/4T-selection

Ignition method and

process selection

Downslope

Pulse frequency

Minilog-function

selection, minilog current

adjustment

Minilog-functions not in use

Current upslope time adj.

continous welding

Continous welding selection

Pulse welding selection and

pulse ratio adjustment

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