Kemppi Master Tig Ac-Dc 2000 2500-w 3500w Inverteres Hegeszto SM
Kemppi Master Tig Ac-Dc 2000 2500-w 3500w Inverteres Hegeszto SM
Kemppi Master Tig Ac-Dc 2000 2500-w 3500w Inverteres Hegeszto SM
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
4
Technical data
5
Switches and connectors
Main switch
TIG-torch connection
Main switch
Shielding gas connection
TIG-torch connection
6
Switches and connectors
Main switch
Shielding gas connection
TIG-torch connector
Main switch
TIG-torch connector
Test switch
Function panels
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 %
Minilog-panel
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.
10
Jumper functions
Jumper ON OFF
J01 Upslope angle is constant, time is dependant Upslope set time remains constant, not
Upslope on the set value. depending on the set value.
J02 Downslope angle is constanttime is Downslope set time remains constant, not
Downslope dependant on the set value. depending on the set value.
J03 TIG antifreeze is on. TIG antifreeze is not on.
TIG antifreeze
J04 Manual AC balance adjustment. Balance automatics is on.
AC balance
J05 Tacking automatics is disabled. Tacking automatics is enabled.
Tacking automatics
J06 The downslope drops to minimum current The downslope drops to the end level,
Downslope cut-off (3A DC, 10A AC). which is 20% of the welding current.
level
J07 OCV is 39V. (22V/VRD) OCV is 70V.
OCV
J08 In the ending of the 4T function the Normal 4T function.
“china logic” 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).
J09 Inverter frequency is 18 kHz on the whole Inverter frequency is 18kHz/36kHz on
Inverter frequency current level. MMA.
J10 Hot/soft–start is in use wit TIG 2T-function. Hot/soft–start is not in use with TIG 2T-
2T hot/soft-start function.
J11 Hot/soft–start time with 2T-function.
2T hot/soft–start Adjustment range is 0,0- 9,9 s.
time adjustment
J12 On 2T the downslope is not cut-off by a On 2T the welding is stopped by a short
2T downslope short (nor long) press on the switch. pres on the switch during the downslope.
J13 On AC-TIG the height of the pos. half-cycle On AC-TIG the height of the pos. half-
AC-welding positive is the same as the negative half-cycle´s cycle depends on the set value and balance
half-cycle height. adjustments.
J14 Torch switch short press time limit is 0,3 s. Torch switch short press time limit is 0,7 s.
Start switch short
press
J15 AC-TIG-welding is started with a negative AC-TIG-welding is started with a positive
AC-TIG start cycle half-cycle. half-cycle.
J16 Length adjustment for the DC start of the Factory setting is 1.
AC-TIG start cycle positive half cycle in AC-TIG 0.0 .... 2.0.
length
J17 MMA ignition pulse height adjustment 0.0 Factory setting is 1.
MMA ignition pulse ..... 2.0.
J18 - -
J19 - -
11
Error codes
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-power sources offer 3 different types of function panels; basic panel, minilog-
panel and pulse panel.
UG2
C2 V2
t
UG2 UG3
t
C3 V3 U1
U1 UG3
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
R001
T003
TIG
T001
V5
V4
V6
UG6
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.
P001
P
14
Filter cards
Information of overvoltage to
control cards A002 and A001
L1
L1
L2 To primary rectifier
L3
DC link +
DC link -
L3
+ 15 V
Overvoltage watch
Protection circuits against wrong supply voltage
GND
15
Filter cards
+ 15 V
Watch
GND
Information of overvoltage to
control cards A002 and A001
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.
X8
X5 X2
X4 X3
16
Mastertig 2000 AC/DC Z001
Filter card layout
X3
X1
X15
X7
X9 X5
X11
X13
X19
R3
X24
X25
X16
X22
X18 X23
X6
X7
X1
X20
X4 X11
X5 X10
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.
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
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.
X1
X6
X4
X3
X2
X9
X2
X1
X3 X5 X4
3/E1 X5 X8
X9 X9 X10 X7 X7
X5
X5
X4
20
Mastertig 3500 AC/DC Z001
Voltage selector switch
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.
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
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.
X4
X13
X12
X11
X5 X2 X1
Coolant overheat
warning lamp
Liquid-/gas cooling
Control selection switch
Cooling unit start
To Reed-relay K001
GND
X1
K1 X2
25
Control card A001 connectors
X1/1 Machine size detection (1600/2500)
X1/2 Set value from the remote controller
X1/3 Process selecting from the remote controller
X1/4 Overheat protections (PTC)
X1/5 Machine size detection (2000)
X1/6 Fan control
X1/7 Net voltage watch from the aux. Transformer T002 secondary
X1/8 -
X1/9 Welding current; DC+ or AC positive half cycles
X1/10 Welding current; DC- or AC negative half cycles
X1/11 Welding voltage; DC+ or AC positive half cycles
X1/12 Welding voltage; DC- or AC negative half cycles
X1/13 Net overvoltage watch
X1/14 Control amplifier (N6-A) output
X1/15 TIG-torch switch
X1/16 AC TIG auxiliary pulse control
26
Control card A002 functions / connectors
28
Control card A002 layout
3,15 AT
X8 X22
X7
X1
X6
X5
X10
X20
R44
X2 Inverter frequency
X14
R119
Max current DC+
X9
X3 R118
Max current DC-
X4 X11
X8 X22
X7
X1
X6
X5
X10
X20
R44
X2 Inverter frequency
X14
X9
X3 R118
Max current
X4 X11
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
31
Control card A004 functions / connectors
X4 X3
X2
X1
32
Structure
A003 T002
S001
A002
Z001
A001
VG102
M001, M002
T001
L1 GA001
T003
Y001
A004
R001
Z002
S001
A002
Z002
A001
T002
S002
Z004
T003
A004
K001
S003
VG103
A005
M003
S001
A002 Z002
A001 T002
Y001
VG101 GA001
Z001
L1 M001
T001
C002
S002
T003
K001
A004
VG103
T004
G002
T005 A005
M003
35
Mastertig 3500W AC/DC
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.
After startup the fans remain rotating. Bad contact in the flat cable between Check flat cables and connectors X1 and
Panel not operating. function panel and control card A002. X2.
Err 1 error message is shown on the Power sources output voltage has risen Check the condition of the control card
display. over 90 V for more than 4 seconds. A003.
The net fuse gets burnt during startup. A faulty supply cable. Check and replace the supply cable as
necessary.
A faulty secondary circuit component. Check the diode cards, secondary IGBT
and control card A003).
36
Troubleshooting diagram
PROBLEM POSSIBLE CAUSE REMEDY
The cooling unit doesn´t work. Fuse F002, 2A has burnt. Check / replace the fuse as necessary.
The cooling unit doesn´t start by the test
switch. Faulty aux. Transformer T005. Check the aux. Transformer T005
primary and secondary voltages. Check
the filter card Z004 (2500W).
The missing coolant pressure warning Coolant level too low. Check the coolant level.
lamp H001 is on..
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.
The system has an air bubble blocking Check the coolant level in the reservoir.
the circulation. Coolant level too low. Hint: Blow compressed air into the
The coolant will not circulate by the test reservoir. The filler neck can be block
switch SW301. by hand.
AC TIG-welding doesn´t work. Th e arc A faulty control card A003. Check / replace control card A003.
dies after a short period of welding.
In AC-welding the second half-cycle is A faulty control card A003. Check if the process is changed on
missing. DC+ or DC- method is control card A003. Replace the card as
inoperative. necessary.
A faulty secondary unit; IGBT or diode Check / replace secondary unit faulty
cards. components.
37
Net voltage operational limits
38
Process selection from the remote controller, voltage on connector X1/3
Fans on
41
AC TIG-welding auxiliary pulse control, voltage on connector X1/16
42
Solenoid valve Y001 control, voltage on connector X2/1
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
43
PWM-control enabling, voltage on connector X2/4
DC+ DC-
AC 50 Hz, MMA
44
AC 200 Hz, TIG
Secondary IGBT control, voltage on connector X2/5
45
Cooling unit monitorings, voltage on connector X2/14
36 kHZ 18 kHZ
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.)
Fan on
100 A 200 A
350 A
49
Measurings from control card A002 connector X10
50
Secondary IGBT control, voltage on connector X10/1
MMA TIG
51
AC TIG auxiliary pulse control, voltage on connector X10/10
53
Measurings from control card A003 connector X3
DC+ DC-
AC 50 Hz, MMA
54
Secondary IGBT control, voltage on connector X3/1-4
Min Max
56
Process selection from remote controller, voltage on connector X8/1-4
MMA TIG
57
IGBT gate pulses, voltage on connector X3/1-2 (A002)
60
T001 primary voltage 10 A
Main transformer T001 primary voltage
10 kΩ
TIG
22 nF U2
65
Secondary voltage U2 using a low-pass filter
AC 10 A 50 Hz,MMA
70
IGBT gate control 100 A
IGBT gate pulses, voltage on connector X3/1-2 (A002)
10 kΩ
TIG
22 nF U2
73
Secondary voltage U2 using a low-pass filter
AC 10 A 50 Hz, MMA
AC 100 A 50 Hz,MMA
74
Secondary voltage U2 using a low-pass filter
77
IGBT gate control 10 A
IGBT gate pulses, voltage on connector X3/1-2 (A002)
AC 10 A 50 Hz, MMA