Kemppi Mastertig acdc 1600 Bedienungsanleitung

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

The signal lamps of machine are not

switched on and LEDs are not on in

the function panel.

Blown fuse(s) in mains supply line *).

Faulty main supply cable.

Faulty main switch S001.

Malfunctioning auxiliary transformer

T002 or loose connection.

Faulty EMC filter card Z002.

Check all three supply voltage

phases so that the fuses are not

blown, change if needed.

Check/repair faulty main supply

cable.

Check the main supply voltage

before and after main switch, change

switch if needed.

Check the transformers supply and 0

V lines, change T002 if needed.

Check the mains supply line voltage

from Z002. Change PCB if need.

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.

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

PROPERLY CHANGE THE PANEL

MEMBRANE

The machine will not start, and the

signal LED in function panel for

over/under/wrong supply voltage is

switched on.

Uin Err message in the main

display

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.

Short circuit in primary part of the

machine.

Short circuit in secondary part of the

machine.

Check/repair faulty main supply

cable.

Check/change the main switch,

primary rectifier, primary IGBT unit

and inverse parallel diode.

Check/change the secondary rectifier

unit (diode blocks) and secondary

IGBT unit. See also

TROUBLESHOOTING FOR

POWER SEMICONDUCTORS.

Err 1 message in the main display. 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.

TECHNICAL SERVICE MANUAL FOR MASTERTIG ACDC

TROUBLESHOOTING CHART

PROBLEM CAUSE REMEDY

The cooling unit is not operational

or H001 light is on.

The water doesn’t circulate by switch

SW302.

Water doesn’t return back to the

tank.

Blown fuse F002 2A.

Broken or faulty auxiliary-

transformer T005.

Broken pressure switch S002.

Pressure switch set value is

unsuitable for the TIG torch which

is in use (other than original Kemppi

torch).

Air bubbles in the system.

Leakages in the cooling system.

Pump motor 5µstarting capacitor

C004 is faulty.

Broken or faulty PCB A005 .

Check and change the fuse if

needed.

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.

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.

Adjust the pressure set value from

the adjustment screw, of pressure

switch according following

instructions:

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.

Blow compressed air into tank,

closing the filling hole by hands is

enough.

Check/repair the connection of

cooling system connector by

connector. Repair the system if

needed.

Check and change the capacitor if

needed.

Change/repair PCB A005.

The solenoid valve Y001 is not

operating // stuck open

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.

Faulty function panel.

Selection for remote unit type is not

correct.

Fuse F001, 0.8A, blown.

Check and repair the remote control

unit and cable according to TABLE

Change PCB A003 in Mastertig

ACDC.

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.

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.

There are occasional disturbances

during welding, set value is not

stable or arc is intermittent.

Arc is stopping intermittently.

Remote control unit is faulty

Faulty start switch in TIG torch.

Broken/faulty TIG torch, loose start

wire(s) in TIG torch.

Faulty Reed relay, K001.

Check/repair the control cable and

remote control unit according to

TABLE 3.

Check and change the start switch if

needed. See also TABLE 2.

Check and tighten the start wire(s)

inside the TIG torch.

Check it by opening the connector

X009, change reed relay if needed.

Welding quality is bad in all methods:

•arc is not stable

•bad arc start

•not enough arc voltage

•lack of power

One mains phase is missing or

mains cable is cut or loose.

Faulty main switch, S001, or primary

rectifier, VG101/G001.

Faulty capacitor C003.

Blown diode(s) in the secondary

rectifier G002, G003 or G004.

Gas is missing or gas leakage in the

TIG torch.

Broken/untightened earth cable or

earth clamp.

Check all mains phases from

terminal block X001. Change mains

fuse if needed, tighten mains cables.

Check using multimeter that S001 is

all right, check also that all diodes in

primary rectifier are functional.

Check/change capacitor C003.

Check and change diode blocks

according to APPENDIX 1.

Check gas flow and solenoid valve

as described earlier. Repair/change

TIG torch if needed.

Check and change the earth clamp

and the cable if necessary.

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.

Broken HF-transformer T003.

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.

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.

Machine is creating high pitched or

rattling sound.

Faulty control card A002 or A003.

Faulty IGBT in primary or secondary

inverter.

Faulty gate IGBT connection in

control card A002 or A003.

Check that control of selecting

welding method is working from the

PCB A003, see PICTURE 1.

Check according following text;

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

UP SLOPE TIME DEPENDS ON

SET VALUE OF CURRENT

UP SLOPE TIME IS INDEPENDENT OF SET

VALUE OF CURRENT

J02

DOWN SLOPE

DOWN SLOPE TIME DEPENDS

ON SET VALUE OF CURRENT

DOWN SLOPE TIME IS INDEPENDENT OF

SET VALUE OF CURRENT

J03

TIG ANTIFREEZE

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

TACK WELDING IS AUTOMATIC DOWN SLOPE FUNCTIONS IMMEDIATELY

J06

DOWN SLOPE CUT OFF

LEVEL

DOWN SLOPE CUT OFF LEVEL

IS MINIMUM CURRENT

DOWN SLOPE CUT OFF LEVEL IS 20 %

OF SET VALUE

J07

OPEN CIRCUIT VOLTAGE

IS 70 V

OPEN CIRCUIT VOLTAGE IS C. 39.5 V

J08

“CHINA LOGIC”

TIG WELDING IN 4T

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

HOT/ SOFT START TIME IN 2T

LOGIC. ADJUSTMENT RANGE

IS 0,0-9,9 SECONDS

J12

2T Downslope

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

IN 2T THE WELDING IS ENDED DURING

DOWNSLOPE WITH A SHORT PULL ON

THE TRIGGGER

J13-15 NOT IN USE

JO16

POSITIVE START CYCLE OF

AC-TIG

ADJUSTMENT FOR LENGTH OF

POSITIVE START CYCLE,

FACTOR 0.0 2.0

FACTORY SETTING IS 1

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

X1/1 IDENTIFICATION OF THE SIZE OF THE MACHINE

X1/2 SET VALUE FROM THE REMOTE CONTROL UNIT

X1/3 SELECTION OF METHOD FROM THE REMOTE CONTROL UNIT

X1/4 THERMAL PROTECTION(PTC)

X1/5 NOT IN USE

X1/6 CONTROL OF COOLING FANS

X1/7 CONTROL OF MAINS SUPPLY VOLTAGE FROM T002 SECONDARY WINDING

X1/8 NOT IN USE

X1/9 WELDING CURRENT ; POSITIVE HALF-CYCLES OF DC+ OR AC

X1/10 WELDING CURRENT ; NEGATIVE HALF-CYCLES OF DC- OR AC

X1/11 WELDING VOLTAGE ; NEGATIVE HALF-CYCLES OF DC- OR AC

X1/12 WELDING VOLTAGE ; POSITIVE HALF-CYCLES OF DC+ OR AC

X1/13 CONTROL OF MAINS VOLTAGE

X1/14 OVER CURRENT

X1/15 SWITCH OF TIG TORCH

X1/16 ADDITIONAL AC PULSE FOR TIG

X2/1 SOLENOID VALVE

X2/2 CONTROL OF TIG SPARK

X2/3 NOT IN USE

X2/4 PWM POSSIBLE

X2/5 CONTROL OF SECONDARY IGBT

X2/6 CONTROL OF SECONDARY IGBT

X2/7 +16 V

X2/8 +15 V

X2/9 +5 V

X2/10 +5 V

X2/11 GND

X2/12 GND

X2/13 START OF COOLING UNIT

X2/14 STOP OF COOLING UNIT

X2/15 NOT IN USE

X2/16 NOT IN USE

TECHNICAL SERVICE MANUAL FOR MASTERTIG ACDC

TABLE 2. CONNECTOR XW101 IN MASTERTIG ACDC

PIN NUMBER SIGNAL VALUE DESCRIPTION

A3.5 VAC start not active

0 V start is active

Torch start switch

B3.5 VAC start not active

0 V start is active

Torch start switch

C--

D--

TABLE 3. CONNECTOR XW102 IN MASTERTIG ACDC

PIN NUMBER SIGNAL VALUE DESCRIPTION

A--

B30 VAC Operating voltage for external

equipment, fuse 0.8 A

C30 VAC Operating voltage for external

equipment, fuse 0.8 A

D--

E+5 VDC Voltage reference of remote control

(upper end of the potentiometers)

F0 V GND (lower end of potentiometers)

G--

H0 - +5 VDC Set value for power source

I+2 VDC=TIG

+5 VDC=MMA

Selection of characteristic TIG/MMA curve

J--

TABLE 4. OVER AND UNDER VOLTAGE LIMITS, (WHEN OCV)

SUPPLY VOLTAGE LOWER LIMIT UPPER LIMIT

MASTERTIG ACDC 1600

230 VAC 165 VAC 270 VAC

MASTERTIG ACDC 2500

230 VAC 175 VAC 270 VAC

400 VAC 300 VAC 460 VAC

460 VAC 340 VAC 530 VAC

MASTERTIG ACDC 3500

400 VAC 365 VAC 460 VAC

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