Kemppi MASTERTIG AC/DC 2500W Service Manual Download Page 18 | Manualshive

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MASTERTIG AC/DC 1600

27.11.2001/V161601

1027620 C/1916140

Order no.

Part

Description

Pc.

4295710

A002

CONTROL CARD

A002 MASTERTIG AC/DC

1

4277540

A003

CONTROL CARD

MAS.TIG AC/DC A003

1

4280540

A004

CONTROL CARD

MAS.TIG AC/DC A004

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

9771530

X005

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

9770458

PLUG 6 POLES

1

9770460

PLUG 15 POLES

1

9770462

CONTACT , MALE

1

9770464

CONTACT, FEMALE

1

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Summary of Contents for MASTERTIG AC/DC 2500W

Page 1: ...TECHNICAL SERVICE MANUAL FOR MASTERTIG ACDC MACHINES ...

Page 2: ... 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 ...

Page 3: ...ion 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...

Page 4: ...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 RELE...

Page 5: ... 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...

Page 6: ...onent 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 C...

Page 7: ...FF LEVEL DOWN SLOPE CUT OFF LEVEL IS MINIMUM CURRENT DOWN SLOPE CUT OFF LEVEL IS 20 OF SET VALUE J07 OPEN CIRCUIT VOLTAGE 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 FREQ...

Page 8: ...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...

Page 9: ...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...

Page 10: ...ernal 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 0 V GND lower end of potentiometers G H 0 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 MASTE...

Page 11: ...URE 1 LEDS IN PCB A003 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 MASTERTIG AC DC A003 H1 H2 X1 T3 T2 T1 X8 X5 X3 V47 L1 X4 X10 X12 X11 X7 R57 R77 ...

Page 12: ... PICTURE 2 TRIMMERS IN PCB A002 MASTERTIG AC DC A002 F2 F4 X20 X14 X9 X11 X4 X3 T1 X2 X1 X10 X8 N4 N1 N2 R44 R118 R119 X22 X5 X6 X7 TRIMMERS R44 ADJUSTMENT FOR BASIC FREQUENCY R118 ADJUSTMENT FOR DC MAX CURRENT R119 ADJUSTMENT FOR DC MAX CURRENT ...

Page 13: ...OR MASTERTIG ACDC PICTURE 3 PRESSURE ADJUSTMENT SCREW Adjustment screw for adjusting correct set value for pressure PICTURE 4 MAIN CIRCUIT OF MASTERTIG ACDC G001 S001 VG101 R001 T003 T001 VG201 VG202 X004 X005 G002 L001 TIG MMA ...

Page 14: ...k 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 be...

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Page 18: ...NSFORMER 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 9771530 X005 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...

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Page 22: ...RY 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 2 4262810 X006 FLAT CABLE L 175 1 9563002 Y001 SOLENOID VALVE 1 9755615 ZC213 CAPACITOR 470 UF 4 4281560 Z001 FILTER CARD 1 4282130 Z002 MAIN CIRCUIT CAR...

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Page 26: ...SFORM 1 2062420 T003 SPARK TRANSFORMER MASTERTIG 2800 3500 1 9777537 T004 CURRENT TRANSFORMER 1 250 PRO 1 9770116 XW101 MACHINE SOCKET 1 9770105 XW102 CONTROL CONNECT 4 POLES FEMALE 1 4292780 X003 CONIC COUPLING R 1 4 M 8X1 1 9771530 X004 MACHINE SOCKET 50 70 2 4262810 X006 FLAT CABLE L 175 1 9563002 Y001 SOLENOID VALVE 1 4277550 Z001 MAIN CIRCUIT CARD MTIG AC DC 2500 1 4282080 Z002 FILTER CARD 1 ...

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Page 31: ...0 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 4260200 R001 SHUNT RESISTOR MASTER 1500 2200 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...

Page 32: ...41513 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 3133020 024 FOOT F COOL PROFIL 1 4280560 025 FAST PC F COOL PROF 1 4257910 026 CONIC HOSE COUPLING R3 8 1 2 KL 1 3140360 CIRC...

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Page 37: ... 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 9544214 M001 COOLING FAN MASTER 2800 3500 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 4260200 R001 SHUNT RESISTOR...

Page 38: ...CDC 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 4280560 025 FAST PC F COOL PROF 2 9373216 026 RUBBER HOSE 13 MM 2 46 93732...

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