Kemppi MASTERTIG AC/DC 2500W, Service Manual

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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
3 .
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.