Technical Service Manual For Mastertig Acdc Machines

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.
TROUBLESHOOTING CHART
PROBLEM CAUSE REMEDY
The MASTERTIG ACDC won’t start Blown fuse(s) in mains supply line *). Check all three supply voltage
at all. Internal water cooler not phases so that the fuses are not
operational blown, change if needed.
The signal lamps of machine are not Faulty main supply cable. Check/repair faulty main supply
switched on and LEDs are not on in cable.
the function panel.
Faulty main switch S001. Check the main supply voltage
before and after main switch, change
switch if needed.
Malfunctioning auxiliary transformer Check the transformers supply and 0

T002 or loose connection. V lines, change T002 if needed.
Faulty EMC filter card Z002. Check the mains supply line voltage
from Z002. Change PCB if need.
When the machine is switched on Broken function panel or loose Check the flat cables and connectors
the cooling fan continuously rotates connection between panel and PCB from panel and A002, X1 and X2.
and the function panel does not A002. Change the function panel if needed.
work, the LED’s are not on. NOTE! IF SOME FUNCTIONS OF PANEL
ARE MISSING, OR IT IS NOT WORKING
Some functions from the panel are PROPERLY CHANGE THE PANEL
not working. MEMBRANE
The machine will not start, and the The machine is connected to wrong Unplug the machine from the mains
signal LED in function panel for supply voltage. supply and select the correct voltage
over/under/wrong supply voltage is from the voltage change-over switch
switched on. which is located under the function
panel.
Uin Err message in the main
display
Short breaks in the welding arc and Overvoltage in mains supply line. Check the mains supply line. The
over/under/wrong supply voltage approx. voltage limits are mentioned
LED is on during these breaks 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 Check/change the main switch,

machine. primary rectifier, primary IGBT unit
and inverse parallel diode.
Short circuit in secondary part of the Check/change the secondary rectifier

machine. 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 IGBT V47, which is located in control
been over 90 volts more than 4 card A003 PICTURE 1., is faulty.
seconds. Check and change the pcb or IGBT.
The cooling unit is not operational Blown fuse F002 2A. Check and change the fuse if
or H001 light is on. needed.
The water doesn’t circulate by switch

SW302. Broken or faulty auxiliary- Check first the supply voltage of
transformer T005. transformer from Z004, connector
Water doesn’t return back to the 1=230V, 2=400, and 3=460V. Then
tank. 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 Adjust the pressure set value from
unsuitable for the TIG torch which the adjustment screw, of pressure
is in use (other than original Kemppi switch according following
torch). 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
Air bubbles in the system. MORE DISTURBANCES.
Blow compressed air into tank,

closing the filling hole by hands is
Leakages in the cooling system. enough.
Check/repair the connection of

cooling system connector by
connector. Repair the system if
needed.
Pump motor 5µ starting capacitor Check and change the capacitor if
C004 is faulty. needed.
Broken or faulty PCB A005 . Change/repair PCB A005.
The solenoid valve Y001 is not Faulty solenoid valve Y001 or Check the 24 VDC from A002
operating // stuck open broken PCB A002. connector X9 between pins 1and 2.
If it is ok, change the solenoid valve.
Remote control unit is not operating Defective remote control unit, faulty Check and repair the remote control
properly. control cable or faulty control card unit and cable according to TABLE
A003 in Mastertig ACDC. 3.
Change PCB A003 in Mastertig
ACDC.
Faulty function panel.
Check the function panel, see
TABLE 1, that the switching for
selection for local/remote is working.
Change the panel membrane if
needed.
Selection for remote unit type is not
correct. See the paragraph SELECTION OF
REMOTE CONTROL UNIT.
Fuse F001, 0.8A, blown.
Check and change the fuse if
necessary.
Machine is overheating. Signal lamp Faulty cooling fan(s) or PCB A002. Check the 24 VDC voltage from fan
for thermal protection is on even if connectors: X9 between pins 3 and
the duty-cycle time has not been Loose connector. 4, another between 6 and 7, if it is
exceeded. all right change the fan(s), if it is
not change the PCB.
There are occasional disturbances Remote control unit is faulty Check/repair the control cable and
during welding, set value is not remote control unit according to
stable or arc is intermittent. 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 Check and tighten the start wire(s)
wire(s) in TIG torch. inside the TIG torch.
Faulty Reed relay, K001. Check it by opening the connector

X009, change reed relay if needed.
Welding quality is bad in all methods: One mains phase is missing or Check all mains phases from
mains cable is cut or loose. terminal block X001. Change mains
• arc is not stable fuse if needed, tighten mains cables.
• bad arc start
• not enough arc voltage Faulty main switch, S001, or primary Check using multimeter that S001 is
• lack of power rectifier, VG101/G001. 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 Check and change diode blocks

rectifier G002, G003 or G004. according to APPENDIX 1.
Gas is missing or gas leakage in the Check gas flow and solenoid valve
TIG torch. as described earlier. Repair/change
TIG torch if needed.
Broken/untightened earth cable or Check and change the earth clamp

earth clamp. and the cable if necessary.
Porosity in the weld joint. Shield gas flow is not correct, Check the gas flow; adjust correct
leakage in the gas hose or faulty flow according welding parameters
solenoid valve. 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.
If the voltage from PCB is all right

Broken HF-transformer T003. change the HF-transformer T003.
Welding characteristics are bad Additional pulse to ignite the positive Check the function of control card
when welding method is AC TIG. half cycle is missing. A003. The pulse circuit driving
component is small IGBT V47.
Check and change the IGBT if
needed.
Positive or negative half cycle is Faulty control card A002 or A003. Check that control of selecting
missing, or both are missing. welding method is working from the
PCB A003, see PICTURE 1.
Machine is creating high pitched or
rattling sound. Faulty IGBT in primary or secondary Check according following text;
inverter.
Primary inverter is VG 101.
Faulty gate IGBT connection in
control card A002 or A003. 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 Wrong security code. The locked panel can be unlocked at
locked. an authorised KEMPPI service repair
shop with a special code . The
unlock code is available only in
these places.
Maximum positive or negative Wrong/changed adjustment in Maximum positive and negative

current adjustment is incorrect. control card A002. current can adjust from A002, see
also PICTURE 2.
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 UP SLOPE TIME IS INDEPENDENT OF SET

UP SLOPE SET VALUE OF CURRENT VALUE OF CURRENT
J02 DOWN SLOPE TIME DEPENDS DOWN SLOPE TIME IS INDEPENDENT OF

DOWN SLOPE ON SET VALUE OF CURRENT SET VALUE OF CURRENT
J03 TIG ANTIFREEZE IS ON TIG ANTIFREEZE IS OFF

TIG ANTIFREEZE
J04 MANUAL AC BALANCE SMART BALANCE FUNCTION IS IN USE,

AC BALANCE CONTROL IS IN USE SCALE OF PANEL IS IN USE
J05 TACK WELDING IS AUTOMATIC DOWN SLOPE FUNCTIONS IMMEDIATELY

TACK WELDING
J06 DOWN SLOPE CUT OFF LEVEL DOWN SLOPE CUT OFF LEVEL IS 20 %
DOWN SLOPE CUT OFF IS MINIMUM CURRENT OF SET VALUE
LEVEL
J07 OPEN CIRCUIT VOLTAGE OPEN CIRCUIT VOLTAGE IS C. 39.5 V

OPEN CIRCUIT VOLTAGE IS 70 V
J08 POSSIBILITY TO PRESET NORMAL 4T FUNCTION

“CHINA LOGIC” STARTING CURRENT,
TIG WELDING IN 4T WELDING CURRENT AND
END CURRENT
J09 INVERTER FREQUENCY IS 18 INVERTER FREQUENCY IS 18 KHZ/ 36

Inverter Frequency KHZ IN THE WHOLE CURRENT KHZ IN MMA!
RANGE
J10 HOT/ SOFT START IS IN USE

2T Hot/ soft start WITH TIG 2T LOGIC
J11 HOT/ SOFT START TIME IN 2T

2T Hot/ soft start time LOGIC. ADJUSTMENT RANGE
setting IS 0,0-9,9 SECONDS
J12 IN 2T THE DOWNSLOPE IN 2T THE WELDING IS ENDED DURING
2T Downslope DOESN´T END WITH A SHORT DOWNSLOPE WITH A SHORT PULL ON
OR A LONG PULL, SO THE THE TRIGGGER
WELDING CURRENT CAN BE
TAKEN UP AND DOWN WITH A
SHORT PULL ON THE TRIGGER
J13-15 NOT IN USE

ADJUSTMENT FOR LENGTH OF FACTORY SETTING IS 1
JO16 POSITIVE START CYCLE,
POSITIVE START CYCLE OF FACTOR 0.0 2.0
AC-TIG
JO17 ADJUSTMENT OF MMA FACTORY SETTING IS 1
MMA IGNITION PULSE IGNITION PULSE (0,0-2,0)
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.

TABLE 1. FUNCTION SIGNALS CONNECTORS X1 AND X2 OF PCB A001
PIN NUMBER DESCRIPTION
X1
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
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
TABLE 2. CONNECTOR XW101 IN MASTERTIG ACDC
PIN NUMBER SIGNAL VALUE DESCRIPTION
A 3.5 VAC start not active Torch start switch

0 V start is active
B 3.5 VAC start not active Torch start switch
0 V start is active
C - -
D - -
TABLE 3. CONNECTOR XW102 IN MASTERTIG ACDC
PIN NUMBER SIGNAL VALUE DESCRIPTION
A - -
B 30 VAC Operating voltage for external
equipment, fuse 0.8 A
C 30 VAC Operating voltage for external
equipment, fuse 0.8 A
D - -
E +5 VDC Voltage reference of remote control
(upper end of the potentiometers)
F 0V GND (lower end of potentiometers)
G - -
H 0 - +5 VDC Set value for power source
I +2 VDC=TIG Selection of characteristic TIG/MMA curve
+5 VDC=MMA
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
PICTURE 1. LEDS IN PCB A003
MASTERTIG AC/DC A003

X8
X7
T1
X5
H1
T2 X3
X1
H2
T3 V47
R77 R57
X10
X11 X4
L1
X12
LEDs, are on when machine is generating OCV
H1 H1 IS ON WHEN THE MACHINE IS IN DC- TIG OR MMA

H2 H2 IS ON WHEN THE MACHINE IS IN AC OR DC + TIG OR MMA
PICTURE 2. TRIMMERS IN PCB A002
MASTERTIG AC/DC A002 X22

X8
X7
X1 N4 N1 N2 F2 F4 X6
X5
X10
X20
X14
X2
R44
T1
R119 X9
X11
X3 X4 R118
TRIMMERS
R44 ADJUSTMENT FOR BASIC FREQUENCY

R118 ADJUSTMENT FOR DC- MAX CURRENT
R119 ADJUSTMENT FOR DC+ MAX CURRENT
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
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.
27.11.2001/V161601 1027620 C/1916140
MASTERTIG AC/DC 1600
Order no. Part Description Pc.
4295710 A002 CONTROL CARD A002 MASTERTIG AC/DC 1
4277540 A003 CONTROL CARD MAS.TIG AC/DC A003 1
4283150 C001 CAPACITOR C001 AC/DC 1
9772516 F001 FUSE 0,8A DELAYED 5 X 20 1
9772551 FUSE BOX + NUT 1
4281530 GA001 DIODE CARD 1
4286000 VG101 SPARE PART IGBT 1
9750126 VG102 DIODE BRIDGE 1
4280860 G001 PRIMARY UNIT 1
3139530 G002 SECONDARY UNIT 1
4290890 VG201 IGBT, SECONDARY AC/DC 1
4280880 G003 SECONDARY UNIT G003 MTIG 1600 ACDC 2
3140270 L001 PRIMARY CHOKE 1
9777115 L003 FERRITE RING 25/15 X 10 1
9544213 M001 COOLING FAN MASTER 1500/2200 1
4260200 R001 SHUNT RESISTOR MASTER 1500/2200 1
9761221 S001 FLIP-FLOP SWITCH WITH PILOT LAMP 1
2067620 T001 MAIN TRANSFORMER 1
9777825 T002 AUXILIARY TRANSFORM. 1
2067590 T003 SPARK TRANSFORMER 1
9777537 T004 CURRENT TRANSFORMER 1:250 PRO 1
9770105 XW101 CONTROL CONNECT. 4 POLES, FEMALE 1
9770116 XW102 MACHINE SOCKET 1
4292780 X003 CONIC COUPLING R 1/4-M 8X1 1
9771530 X004 MACHINE SOCKET 50/70 1
4262810 X006 FLAT CABLE L=175 1
9563002 Y001 SOLENOID VALVE 1
9755615 ZC213 CAPACITOR 470 UF 1
4281560 Z001 FILTER CARD 1
4282130 Z002 MAIN CIRCUIT CARD 1
4282300 001 RUBBER 1
3134270 002 HOSE CONNECTOR R1/8-M12 1
4286030 003 GAS CONNECTOR 1
9377205 004 HOSE CLAMP 1
9370182 005 PLASTIC HOSE 5/8 BLUE 0,25
2067100 006 FOOT 1
2067120 007 HANDLE MTIG 1600/2500 AC/DC 1
4280870 008 HANDLE 1
2067130 009 PROTECTIVE COVER MTIG 1600/2500 AC/DC 1
3139460 010 PLASTIC PIECE 1
4296190 011 STICKER MASTERTIG AC/DC 1
2067260 012 SIDE PLATE LEFT MTIG1600 ACDC 1
2067270 013 SIDE PLATE RIGHT MTIG1600 ACDC 1
3139520 014 COVER MTIG1600 ACDC 1
3133020 015 FOOT F COOL.PROFIL 1
4280560 016 FAST.PC F COOL.PROF. 1
3140350 CIRCUIT DIAGRAM MASTERTIG 1600AC/DC 1
9770456 PLUG 2 POLES 1
9770457 PLUG 3-POLES 1
9770460 PLUG 15 POLES 1
9770462 CONTACT , MALE 1
9770464 CONTACT, FEMALE 1
13.08.2002/V162001 1029860
9772516 F001 FUSE 0,8A DELAYED 5 X 20 1
9772551 F001 FUSE BOX + NUT 1
428086001 G001 PRIMARY UNIT G001 MTIG AC/DC 2000 1
428600001 VG101 SPARE PART IGBT MASTERTIG AC/DC 2000 1
4299800 G002 SECONDARY UNIT G002 MTIG AC/DC 2000 1
4300750 VG201 IGBT, SECONDARY 2PCS 2X200A ACDC2000 1
429089001 VG201 IGBT, SECONDARY 1 PC 2X400A ACDC2000 0
4280880 G003 SECONDARY UNIT G003 MASTERTIG AC/DC 4
3149440 L001 PRIMARY CHOKE MASTERTIG AC/DC 2000 1
9777115 L003 FERRITE RING 25/15 X 10 6
9544221 M001 COOLING FAN MASTER,-TIG MLS 2
9760604 S001 SWITCH 1
2067590 T003 SPARK TRANSFORMER 1
4262810 X006 FLAT CABLE L=175 1
9755615 ZC213 CAPACITOR 470 UF 4
4282130 Z002 MAIN CIRCUIT CARD 1
4282300 001 RUBBER 4
4286030 003 GAS CONNECTOR 1
9377205 004 HOSE CLAMP 2
2067100 006 FOOT 2
2067120 007 HANDLE MTIG 1600/2500 AC/DC 2
4280870 008 HANDLE 1
206726001 012 SIDE PLATE LEFT MASTERTIG AC/DC 2000 1
206727001 013 SIDE PLATE RIGHT MASTERTIG AC/DC 2000 1
3139520 014 COVER MTIG ACDC 1600,2000 1
4280580 017 SPRING MASTERTIG AC/DC 1
3149110 CIRCUIT DIAGRAM MASTERTIG 2000 AC/DC 1
9770460 PLUG 15 POLES 1
27.11.2001/V162501 2068280 C/1916150
9755264 C003 CAPACITOR 75 UF 1
9414086 BOX NUT 1
9772516 F001 FUSE 0,8A DELAYED 5 X 20 1
9772551 FUSE BOX + NUT 1
4286780 VG103 SPARE PART IGBT 2 X 200A 1
9750174 VG101 RECTIFIER UNIT 1
2067020 G001 PRIMARY UNIT MTIG2500 3J ACDC 1
3139440 G002 SECONDARY UNIT MTIG 2500 ACDC 1
3137400 L001 PRIMARY CHOKE L001/MASTER2850 3J 1
9777115 L003 FERRITE RING 25/15 X 10 1
976050201 S001 MAIN SWITCH K60/12 D22,5 1
9760632 S003 V.CHANGE-OVER SW. 1
2062420 T003 SPARK TRANSFORMER MASTERTIG 2800/3500 1
4262810 X006 FLAT CABLE L=175 1
4277550 Z001 MAIN CIRCUIT CARD MTIG AC/DC 2500 1
4282300 001 RUBBER 1
9568913 003 HOSE CONNECTOR R1/8-6ML 1
9377256 004 HOSE CLAMP 1
9370101 005 PVC HOSE 0,25
2067100 006 FOOT 1
2067120 007 HANDLE MTIG 1600/2500 AC/DC 1
4280930 008 HANDLE MTIG 2500 ACDC 1
4282960 012 VOLTAGE STICKER ACDC 1
2067080 015 COVER MTIG2500,3500W ACDC 1
3140360 CIRCUIT DIAGRAM MTIG 2500 AC/DC 1
9770460 PLUG 15 POLES 1
27.11.2001/V162506 2068340 D/1916160
MASTERTIG 2500W ACDC
4279500 A005 CONTROL CARD A002 KWELD 4000W 1
9414086 C003 BOX NUT 1
9755264 C003 CAPACITOR 75 UF 1
9755223 C004 CAPACITOR 8UF/450V AC 1
9772516 F001 FUSE 0,8A DELAYED 5 X 20 1
9772551 F001 FUSE BOX + NUT 1
9772520 F002 FUSE DELAYED 2A 5X20 1
9772551 F002 FUSE BOX + NUT 1
3139440 G002 SECONDARY UNIT MTIG 2500 ACDC 1
9775731 H001 SIGNAL LAMP RED 1
9775729 H002 SIGNAL LAMP YELLOW 1
4249080 K001 REED RELAY 1
3140840 L001 PRIMARY CHOKE 1
9777115 L003 FERRITE RING 25/15 X 10 1
3138320 M003 PUMP-MOTOR COMB. SIMACO 1
9544306 M003 COOLING FAN WING SIMACO 1
9544305 M003 COOLING FAN WING SPECK 1
9540415 M003 REPAIR SET FOR PUMP SIMACO 1
9540411 M003 REPAIR SET FOR PUMP SPECK 1
9761375 SW301 LEVER SWITCH 1
9761323 SW302 CHANGE OVER SWITCH 1
976050201 S001 MAIN SWITCH K60/12 D22,5 1
9761622 S002 PRESSURE SWITCH 1
9760632 S003 V.CHANGE-OVER SW. 1
3141530 T005 TRANSFORMER 1
4262810 X006 FLAT CABLE L=175 1
4292790 X007 CURRENT/WATER CONN. R3/8"/R1/4" 1
4277550 Z001 MAIN CIRCUIT CARD MTIG AC/DC 2500 1
4282300 001 RUBBER 1
9377256 004 HOSE CLAMP 1
9370101 005 PVC HOSE 0,25
2067100 006 FOOT 1
2067120 007 HANDLE MTIG 1600/2500 AC/DC 1
27.11.2001/V162506 2068340 D/1916160
MASTERTIG 2500W ACDC
4282950 012 STICKER GAS/WATER ACDC 1
4282960 013 VOLTAGE STICKER ACDC 1
2067080 016 COVER MTIG2500,3500W ACDC 1
4241513 017 CONNECTION CABLE 1
9592126 018 WATER TANK 1
4237831 019 GAS HOSE D6/R1/8-1.7M 1
9761302 020 PROTECTION SWITCHES'LEVER 1
9581005 021 HEAT EXCHANGER 220X225 SIMACO 1
2069370 022 SIDE PLATE LEFT MTIG2500W,3500WACDC 1
2067360 023 SIDE PLATE RIGHT MTIG2500W,3500WACDC 1
4257910 026 CONIC HOSE COUPLING R3/8-1/2 KL 1
3140360 CIRCUIT DIAGRAM MTIG 2500 AC/DC 1
3140370 CIRCUIT DIAGRAM MTIG-W AC/DC 1
9770460 PLUG 15 POLES 1
27.11.2001/V163505 2069530 B/1916180
MASTERTIG ACDC 3500W
4279500 A005 CONTROL CARD A002 KWELD 4000W 1
9755268 C002 SMOOTHING CAPASITOR 25UF/700VDC 1
9755223 C004 CAPACITOR 8UF/450V AC 1
9772516 F001 FUSE 0,8A DELAYED 5 X 20 1
9772520 F002 FUSE DELAYED 2A 5X20 2
9772551 F002 FUSE BOX + NUT 2
2069290 G002 SECONDARY UNIT MTIG 3500W ACDC 1
4288750 VG201 IGBT, SECONDARY MTIG 3500W ACDC 2
9755118 C101 CAPACITOR 4.7 NF/1000V 1
9753592 R101 VARISTOR 250V 20 MM 1
9753161 R102 RESISTOR 100R 5W 1
4268440 RG003 PTC RESISTOR +90 C 3
9775731 H001 SIGNAL LAMP RED 1
9775729 H002 SIGNAL LAMP YELLOW 1
4249080 K001 REED RELAY 1
3137401 L001 PRIMARY CHOKE MTIG 3500W ACDC 1
9777115 L003 FERRITE RING 25/15 X 10 4
9777121 L005 FERRITE CORE U57/28/16 2
4288500 L006 FERRITE CHOKE 1
3138320 M003 PUMP-MOTOR COMB. SIMACO 1
9544306 M003 COOLING FAN WING SIMACO 1
9544305 M003 COOLING FAN WING SPECK 1
9540415 M003 REPAIR SET FOR PUMP SIMACO 1
9540411 M003 REPAIR SET FOR PUMP SPECK 1
9761375 SW301 LEVER SWITCH 1
9761323 SW302 CHANGE OVER SWITCH 1
976050201 S001 MAIN SWITCH K60/12 D22,5 1
9761622 S002 PRESSURE SWITCH 1
2069320 T001 MAIN TRANSFORMER MTIG 3500W ACDC 1
4288330 RT101 PTC RESISTOR +140 C 1
3143110 T005 AUXIL. TRANSFORMER MTIG 3500W ACDC 1
4219610 X004 CONIC HOSE COUPLING R1/4-6ML 2
4262810 X006 FLAT CABLE L=175 1
4292790 X007 CURRENT/WATER CONN. R3/8"/R1/4" 1
4288230 Z001 MAIN CIRCUIT CARD MTIG 3500W ACDC 1
4288240 Z002 PRIMARY FILTER CARD MTIG3500W ACDC 1
4282300 001 RUBBER 8
9480207 002 CUP SPRING 12.5X6.2X0.7 32
4282030 003 STRAINING BEAM 4
27.11.2001/V163505 2069530 B/1916180
MASTERTIG ACDC 3500W
9433068 004 SLOT-HEADED SCREW M6X25 8
9377200 006 HOSE CLAMP 1
2067100 008 FOOT 4
2067120 009 HANDLE MTIG 1600/2500 AC/DC 2
4282950 014 STICKER GAS/WATER ACDC 1
2069050 015 SIDE PLATE LEFT MTIG 3500W ACDC 1
2069060 016 SIDE PLATE RIGHT MTIG 3500W ACDC 1
2067080 017 COVER MTIG2500,3500W ACDC 1
2069370 018 SIDE PLATE LEFT MTIG2500W,3500WACDC 1
2067360 019 SIDE PLATE RIGHT MTIG2500W,3500WACDC 1
9592126 020 WATER TANK 1
9581005 021 HEAT EXCHANGER 220X225 SIMACO 1
4257910 022 CONIC HOSE COUPLING R3/8-1/2 KL 1
9761302 023 PROTECTION SWITCHES'LEVER 2
3130180 024 FOOT T/6 11
9373216 026 RUBBER HOSE 13 MM 2,46
9373215 027 RUBBER HOSE 10/17 MM 0,68
9377130 028 HOSE CLAMP 13-20 MM 8
3142870 CIRCUIT DIAGRAM MTIG 3500W AC/DC 1
3140370 CIRCUIT DIAGRAM MTIG-W AC/DC 1
9770450 FEMALE CONTACT BODY 2 POLES 1
9770460 PLUG 15 POLES 2

Technical Service Manual For Mastertig Acdc Machines

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Technical Service Manual For Mastertig Acdc Machines

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TECHNICAL SERVICE

MANUAL FOR MASTERTIG

INTRODUCTION / GENERAL MAINTENANCE OF MASTERTIG ACDC

Maintenance of the Mastertig ACDC machine would normally involve a general

The number of systems in operation and the importance of minimize not

PROBLEM CAUSE REMEDY

Malfunctioning auxiliary transformer Check the transformers supply and 0

Short circuit in primary part of the Check/change the main switch,

Short circuit in secondary part of the Check/change the secondary rectifier

PROBLEM CAUSE REMEDY

The water doesn’t circulate by switch

I START PRESSING TEST SWITCH

Blow compressed air into tank,

Check/repair the connection of

PROBLEM CAUSE REMEDY

Faulty Reed relay, K001. Check it by opening the connector

Faulty capacitor C003. Check/change capacitor C003.

Blown diode(s) in the secondary Check and change diode blocks

Broken/untightened earth cable or Check and change the earth clamp

PROBLEM CAUSE REMEDY

If the voltage from PCB is all right

See also PICTURE 4.

Maximum positive or negative Wrong/changed adjustment in Maximum positive and negative

JUMPER NUMBER FUNCTION ON FUNCTION OFF

J01 UP SLOPE TIME DEPENDS ON UP SLOPE TIME IS INDEPENDENT OF SET

J02 DOWN SLOPE TIME DEPENDS DOWN SLOPE TIME IS INDEPENDENT OF

J03 TIG ANTIFREEZE IS ON TIG ANTIFREEZE IS OFF

J04 MANUAL AC BALANCE SMART BALANCE FUNCTION IS IN USE,

J05 TACK WELDING IS AUTOMATIC DOWN SLOPE FUNCTIONS IMMEDIATELY

J07 OPEN CIRCUIT VOLTAGE OPEN CIRCUIT VOLTAGE IS C. 39.5 V

J08 POSSIBILITY TO PRESET NORMAL 4T FUNCTION

J09 INVERTER FREQUENCY IS 18 INVERTER FREQUENCY IS 18 KHZ/ 36

J10 HOT/ SOFT START IS IN USE

J11 HOT/ SOFT START TIME IN 2T

J13-15 NOT IN USE

1. Turn off the machine.

CALIBRATION OF THE PANEL

It is possible to calibrate the current meter of the Mastertig ACDC in DC -

2. Turn off the machine.

8. Check the corrected values from the panel display.

PIN NUMBER DESCRIPTION

X1/1 IDENTIFICATION OF THE SIZE OF THE MACHINE

X2/1 SOLENOID VALVE

PIN NUMBER SIGNAL VALUE DESCRIPTION

A 3.5 VAC start not active Torch start switch

TABLE 3. CONNECTOR XW102 IN MASTERTIG ACDC

PIN NUMBER SIGNAL VALUE DESCRIPTION

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

SUPPLY VOLTAGE LOWER LIMIT UPPER LIMIT

MASTERTIG ACDC 1600

MASTERTIG ACDC 2500

MASTERTIG ACDC 3500

MASTERTIG AC/DC A003

LEDs, are on when machine is generating OCV

H1 H1 IS ON WHEN THE MACHINE IS IN DC- TIG OR MMA

MASTERTIG AC/DC A002 X22

R44 ADJUSTMENT FOR BASIC FREQUENCY

PICTURE 4. MAIN CIRCUIT OF MASTERTIG ACDC