Kemppi MasterTig 3500, MasterTig 2800, MasterTig 2200, MasterTig 1500, Master 2200 Service Manual

Service manual

Ver. 1.0

1400

1500

2200

2800

3500

1500

2200

2800

3500

Contents

General 3

Technical data, switches and connectors 3-6

Mastertig function panels 7-10

Operating principle 11

IGBT gate pulse (2800/3500) 12

Voltage over the lower IGBT (2800/3500) 13

Voltage after the secondary diodes (2800/3500) 14

IGBTgate pulse (1400-2200) 15

Voltage over the lower IGBT (1400-2200) 16

Voltage after the secondary diodes (1400-2200) 17

Troubleshooting 18-20

Power source control card A001 block diagram 21

Mastertig-power source´s TIG-section´s functions 22

Signals between control cards A001 and A002 23

Signals between control cards A002 and A004 23

Control card A001 layout (1400/1500) 24

Control card A001 layout (2000/2200) 24

Control card A001 layout (2800/3500) 25

MSD 1-meter unit layout 25

Control card A002 layout (1500/2200) 26

Control card A002 layout (2800/3500) 26

Control card A004 layout (2800/3500) 27

Control card A001 operation check 27

Control card A002 operation check 28-29

Control card A004 operation check 30

Notes 31

2

General

Master- and Mastertig-power sources are MMA and TIG power sources designed for

demanding professional use.
Master- and Mastertig-power sources are IGBT-inverters, controlled by PWM-principle.
Operation frequency is approx. 18 kHz.

5 power source sizes are available; 1~ 140 A, 1~ 150 A, 3~ 220 A, 3~ 280 A and 3~ 350 A

Technical data, switches and connectors

Master 1400

1

Supply voltage 1∼,50/60 Hz

Connection power 20% ED
60% ED
100% ED

Supply cable/ fuses

Welding current range MMA

Suitable electrode sizes

Welding power adj.
OCV

2

3

220V –10%….240V +6%

140 A/ 6,2 kVA
105 A/ 4,4 kVA
75 A/ 2,9 kVA

3 x 1,5S / 16 A slow

15 A / 20,0 V..140 A / 25,6 V

1,5…..3,25 mm

∅

stepless
Approx. 80 V

1 Main switch S001 and welding current connectors
2 Overheat protection signal lamp
3 Current adj. potentiometer

Efficiency

Idling power
Degree of protection / Casing
class
Weight 10 kg

80% (140 A / 25,6V)

Approx. 10 W
IP 23

3

Master 1500

1

2

3

4

5

Supply voltage 1∼,50/60 Hz

Connection power 20% ED
60% ED
100% ED

Supply cable/ fuses

Welding current range MMA

(TIG

Suitable electrode sizes

1 Main switch S001, welding current connectors and

dynamics adjustment
2 Overheat protection signal lamp
3 Remote controller connection
4 Local / remote control
5 Current adjustment potentiometer

220V –10%….240V +6%

150 A / 6,6 kVA
105 A / 4,4 kVA
75 A / 3,0 kVA

3 x 1,5S / 16 A slow

15 A / 20,5 V..150 A / 26,0 V

5 A / 10,2 V..150 A / 16,0 V)

1,5…..3,25 mm

∅

Welding power adjustment
OCV

Efficiency

Idling power
Degree of protection / Casing
class
Weight 10,5 kg (TIG, 13,5 kg)

Auxiliary devices Remote controllers

stepless
Approx. 80 V

80% (150 A / 26,0 V)

Approx. 10 W
IP 23C

C 100C, C 100D

4

Master 2200

1

1 Main switch S001, welding current connections and

2

3

dynamics adjustment
2 I/0-signal lamp
3 Remote controller connecyor
4 Overheat protection signal lamp

4
5

5 Remote / local control selection
6 Current adjustment potentiometer

6

Supply voltage 3∼,50/60 Hz

Connection power 25% ED
60% ED
100% ED

Supply cable / fuses

Welding current range MMA

(TIG

Suitable electrode sizes

Welding power adjustment
OCV

Efficiency

Idling power
Degree of protection / Casing
class
Weight 12,5 kg (TIG, 16 kg)

Auxiliary devices Remote controllers

380V –10%….415V +6%

220 A / 8,4 kVA
145 A / 5,5 kVA
110 A / 3,5 kVA

4 x 1,5S / 10 A slow

15 A / 20,5 V…220 A / 28,8 V

5 A / 10,2 V…220 A / 18,8)

1,5…4,0 (5,0) mm

∅

stepless
Approx. 80 V

82% (220 A / 28,8V)

Approx. 10 W
IP 23C

C 100C, C 100D

5

Master 2800 and 3500

1

23465

Supply voltage 3∼,50/60 Hz

Connection power 35% ED
60% ED
100% ED

Supply cable/ fuses

Welding current range MMA

(TIG

Suitable electrode sizes

1 Main switch S001 and welding current connectors
2 I/0-signal lamp
3 Overheat protection signal lamp

7

4 Dynamics adjustment
5 Current adjustment potentiometer
6 local / remote control
7 Remote controller connector

380V –10%….415V +6%

280 A / 11,5 kVA
213 A / 8,5 kVA
165 A / 6,0 kVA

4 x 1,5S / 10 A slow

15 A / 20,5 V…280 A / 31,2 V

5 A / 10,2 V…280 A / 21,2 V)

1,5…n. 5,0 mm

∅

380V –10%….415V +6%

350 A / 15,0 kVA
267 A / 11,0 kVA
207 A / 8,0 kVA

4 x 2,5S / 16 A slow

15 A / 20,5 V…350 A / 34,0 V

5 A / 10,2 V…350 A / 24,0 V)

1,5…n. 6,0 mm

∅

Welding power adjustment
OCV

Efficiency

Idling power
Degree of protection / Casing

stepless
Approx. 75 V

83% (280 A/ 31,2 V)

approx. 25 W

stepless
approx. 75 V

83% (350 A/ 34,0 V)

approx. 25 W

IP 23 IP 23
class
Weight 22 kg (TIG, 27 kg) 25 kg (TIG, 30 kg)

Auxiliary devices Remote controllers

C 100C, C 100D, C100T,

MSD 1

Remote controllers
C 100C, C 100D, C100T,
MSD 1

6

Mastertig 1500 and 2200

2

1

Pulse panel

345

1 Main switch S001, dynamics adjustment and welding

current connections
2 Current adjustment potentiometer
3 Overheat protection signal lamp
4 Local / remote control selection
5 Remote controller connector

Pregas time

welding selection,
pulse ratio
adjustment

Pause current Postgas time

2T/4T-selection

Ignition method and process selection

Downslope timePulse frequencyContinous / pulse

7

Minilog-panel

Pause current Post gas time

Pulse frequency

Downslope time

Minilog-operation selection,
minilog-current adjustment

2T/4T-selection

Ignition method and process selection

Current upslope time,
continous welding

Minilog-functions not in use

Pulse welding selection and
pulse ratio adjustment

Continous welding selection

8

Mastertig 2800 and 3500

1

Pulse panel

234

5

1 Main switch S001 and welding current connectors

6

7

2 I/0-signal lamp
3 Overheat protection signal lamp
4 Dynamics adjustment
5 Current adjustment potentiometer
6 Local / remote control selection
7 Remote controller connector

Pregas time

welding selection,
pulse ratio
adjustment

Pause current

Postgas time

2T/4T-selection

Ignition method and process
selection

DownslopePulse frequencyContinous / pulse

9

Minilog-panel

Pause current Postgas time

Pulse frequency

Downslope

Minilog-function
selection, minilog current
adjustment

2T/4T-selection

Ignition method and
process selection

Current upslope time adj.
continous welding

Minilog-functions not in use

Pulse welding selection and
pulse ratio adjustment

Continous welding selection

10

Operation principle

The power stage in Master- and Mastertig- power sources is a traditional half-bridge, where the
intermediate circuit´s dc-voltage is halved by load capacitors C2 and C3. IGBT-transistors are
used as power switches. When both IGBTs are not conductive, no power is transferred. When the
upper IGBT (V2) is conductive, there is positive voltage in the main transformer´s (T1) primary,
and when the lower IGBT (V3) is conductive there is negative voltage in the main transformer´s
(T1) primary.

Power is adjusted by altering the IGBT timings (PWM). The main transformer (T1) secondary
voltages are rectified by a full-wave rectifier.

U

G2

approx. + 320 V (1~) or approx. + 570 V (3~)

C2

C3

U

T1

V2

U

1

U

G2

G3

t

t

U

1

V3

U

G3

U

U

2

2

t

t

Voltage over the lower IGBT V3 with minimum power (3~)

Voltage over the lower IGBT V3 with maximum power (3~)

11

IGBT gate pulse (Master / Mastertig 2800/3500)

A

A

IGBT gate pulse with minimum power (2800/3500). Inverter operating frequency approx. 19 kHz (measuring point A).

A

IGBT gate pulse with maximum power (2800/3500). Inverter operating frequency approx. 19 kHz (measuring point A).

12

Voltage over the lower IGBT (Master / Mastertig 2800/3500)

B

B

Voltage over the lower IGBT with minimum power (2800/3500). Inverter operating frequency approx. 19 kHz (measuring point B).

B

Voltage over the lower IGBT with maximum power (2800/3500). Inverter operating frequency approx. 19 kHz (measuring point B).

13

Voltage after the secondary diodes (Master / Mastertig 2800/3500)

C

C

Voltage over the secondary diodes with minimum power(2800/3500). Frequency is approx. 38 kHz (measuring point C).

C

Voltage over the secondary diodes with maximum power (2800/3500). Frequency approx. 38 kHz (measuring point C).

14

IGBT gate pulse (Master / Mastertig 1400/1500/2200)

D

D

IGBT gate pulse with minimum power (1400/1500/2200). Inverter operating frequency approx. 18 kHz (measuring point D).

D

IGBT gate pulse with maximum power (1400/1500/2200). NOTE. Inverter operating frequency approx. 25 kHz (measuring point D).

15

Voltage over the lower IGBT (Master / Mastertig 1400/1500/2200)

E

D D

Master 1400/1500 Master 2200

E

D

E

Lower IGBT control (Gate pulse; measuring point D / Voltage over the lower IGBT; measuring point E).

16

Voltage after the secondary diodes (Master / Mastertig 1400/1500/2200)

D

Master 1400/1500

F

D

Master 2200

F

F

D

Voltage after the secondary diodes (measuring point F) and lower IGBT gate pulse (measuring point D).

17

Troubleshooting

The machine may be repaired only by an authorized and licensed technician or workshop!

First do a visual check to find the possible loose connectors, broken wires or signs of overheating.

Also check the condition of the welding cables, welding guns / torches and all consumable parts.

Troubleshooting diagram

DISTURBANCE POSSIBLE CAUSE REMEDY

The power source will not start.
MMA open circuit voltage is 0 V

Net fuses have blown

Faulty supply cable

Check the net fuses

Check the supply cable condition

The net fuses blow during
startup.

Faulty main switch

Faulty current adjustment
potentiometer

Faulty local / remote control
selection switch (2200-3500)

Faulty auxiliary transformer

Faulty primary side power
semiconductor

Faulty control card A001

Faulty control card A002
(Mastertig)

Faulty flat cable between
control cards A001 and A002
Faulty primary side power
semiconductor

Faulty main circuit card

Check the main switch condition

Check the potentiometer condition

Check the control method selection
switch condition

Check the auxiliary transformer
condition
Check the condition of the primary
rectifier and the IGBT-module

Check the control card A001
condition (see page 27)

Check the control card A002
condition (see pages 28 and 29)

Check the flat cable condition
(see page 23)
Check the condition of the primary
rectifier and IGBT-module

Check the condition of the
smoothing and load capacitors.

Look for possible signs of
insulation damages on main circuit
card.

Faulty secondary unit

Note! 1-phase Master- and Mastertig-power sources may blow net fuses
during the first startup, without being anything wrong in the power source. This
is because the DC-link capacitors have relatively high charging current! This
phenomenon is found especially with automatic fuses.

Check the secondary diodes
condition.

18

DISTURBANCE POSSIBLE CAUSE REMEDY

The power source will not deliver

A net fuse has blown

Check the net fuses

full power

Faulty supply cable

Check the supply cable condition

The power source will not
operate on TIG

Faulty main switch

Faulty primary side power semi­conductor

Faulty control card A001

Check the main switch condition

Check the primary rectifier and
IGBT-module

Check the correct pulse ratio
adjustment from control card A001
to IGBT gate (see pages 12 and 15)

Faulty main circuit card

Check the main circuit card
capacitors and their connections

Faulty secondary unit

Check the condition the secondary
diodes

Faulty main transformer

Faulty control card A002
(Mastertig)

Check the main transformer ferrites

Check the flat cable signals
between control cards A001 and
A002; pins 1 and 2 against the
card´s GND (see pages 28 and 29)

Faulty flat cable between
control cards A001 and A002

Check the flat cable´s condition

(see page 23)
Check power source´s operation on MMA. Disconnect the flat cable
from control card A001 and connect a shortcircuit loop to the flat cable
connector X3, between pins 1 and 2. If the power source doesn´t work
on MMA , then the TIG process can not work either.

Faulty flat cable between control
cards A001 and A002

Check the flat cable condition
(see page 23)

TIG-spark ignition doesn´t work.
Scratch ignition method is OK.
On MMA the machine works
OK.

Faulty control card A002 Check control card condition

(see pages 28 and 29)

Faulty flat cable between control
cards A001 and A002

Faulty control card A002

Check the flat cable condition
(see page 23)

Check the control card A002
condition

(see pages 28 and 29)
Faulty control card A004
(2800/3500)

Check the control card A004

condition (see page 30)

19

DISTURBANCE POSSIBLE CAUSE REMEDY

TIG-process logic functions are
not working correctly

Faulty adjustment potentiometer

Check the adjustment
potentiometers

Mastertig 3500 W-cooling unit
doesn´t stay on, when operated
by it´s start switch

Mastertig 3500 W-cooling unit
doesn´t start, when operated by
it´s start switch

Faulty flat cable between
control cards A002 and A003

Faulty control card A002

Faulty pressure switch

Faulty control card A005

The fuse F002 has blown

Faulty switch

Faulty auxiliary transformer
T004

Pump is jammed

Faulty startup capacitor

Faulty pump motor

Check the flat cable
(see page 23)

Replace control card A002
(see pages 28 and 29)
Check the pressure switch

Check the control card A005 relays

Check the fuse and the fuse holder

Check the switch

Check the auxiliary transformer
T004

Check and clean the pump

Check the startup capacitor.

Check the pump motor

20

Control card A001 block diagram

Set value

circuit

Current instruction

MMA ignition

Controller and

PWM

development

Gate buffers

Control to IGBT

TIG/MMA

U2

I2

Locking

MMA

dynamics

OCV

adjustment

Actual current value

AV~40

Fan control

Overheat

protection

Power supply

Net voltage

watch

Current information
to TIG

The functions of power source´s control card A001 are built around the PWM-controller SG

3526.

Gate buffer

PWM-controller develops PWM-signals, that are amplified in the gate buffer and taken via a control transformer
to the IGBT-module´s gates.

Set value circuit

Set value circuit prepares the signal coming from the potentiometer suitable for the PWM-controller and protects
the electronics from potentiometer circuit´s insulation faults and possible overvoltages.

MMA ignition

The MMA ignition circuit develops an overcurrent spike to the set value current in order to ease the ignition.

MMA Dynamics

The dynamics circuit develops overcurrent spikes to the set value current during short circuits.

Locking

The locking circuit prevents the MMA ignition current and dynamics operation on TIG.

OCV controller

The OCV circuit controls the power stage during idling so that the power losses are minimized.

Shunt amplifier

Current signal amplifier amplifies the shunt voltage suitable for the PWM-controller.

Fan control

PWM-signal is used to control the fans on/off. During idling the PWMcontroller´s pulse ratio is so low , that the
fans are off. The fans start after 30 seconds from the start of welding, regardless of the welding current level. Post­welding cooling is active for 5 minutes.

Overheat protection

Overheat protection is activated by PTC-resistors.

Power supply

The power supply section forms the auxiliary voltages needed by control card A001. The power supply section
also provides undervoltage watch.

Net voltage watch

Net voltage watch circuit stops the power stage, in case the net voltage rises above certain limit.

21

Mastertig-power source´s TIG-section

The TIG-section provides these programmatic functions:

• Pre- and postgas timings

• Up- and downslopes

• Tacking automatics

• Switch functions (2T/4T)

• Pulse functions

• Pulse led control

• Ignition spark control and watch

• Contact ignition control and watch

• Power source start and set value

24 VAC

+ 16 V

+ 16 V

Operation
voltage
section

Reset­generator

24 VAC

+ 5 V Spark on/off

Controller part

Reset

Solenoid
valve

LED

Spark
generator

10 kV

Operation panel

Start

Start

-indication

22

Signals between control cards A001 and A002 (Mastertig 1500-3500)

1 Current set value from power source (0,5…5 Vdc)

2 Current set value to power source (0,5…5 Vdc)

3GND

4GND

5GND

6GND

7

8 Output voltage information from power source

(OCV on MMA is approx. 75 Vdc)

9

10

11

12

13 MMA/TIG-selection (TIG = 4,5 Vdc, MMA = 0 V)

14 26 Vac from power source

15 26 Vac from power source

16 16 Vac from power source

Signals between control cards A002 and A004 (Mastertig 2800-3500)

5/1 26 Vac

5/2 Spark generator on/off

5/3 Start switch detection

X6/3 (A004) GND

23

Control card A001 layout (Master / Mastertig 1500)

X10X11

X8 X4

Closed

Open

X17

X15 MMA

R70

X16

X15

X2 X3

R48

X18

R98

X1

R47

R49

X15 Scratch-TIG

X16

X17

X18 OCV approx. + 80 V

X18 OCV approx.. + 40 V

R47 Maximum current
R48 MMA ignition current
R49 Minimum current
R70 Inverter frequency
R98 Set value min. (TIG)

Control card A001 layout (Master / Mastertig 2000/2200)

X20

X10X11

X17

R70

X16

X2 X3

R47 Maximum current
R48 MMA ignition current
R49 Minimum current
R70 Inverter frequency
R98 Set value min. (TIG)

X8 X4X5

X15

R48

X18

R47

R98

R49

X14

X13

X12

X1

Closed

Open

X15 MMA

X15 Scratch-TIG

X16 Net voltage 3∼ 400 V

X16 Net voltage 3∼ 460 V

X17 Net voltage 3∼ 460 V

X17 Net voltage 3∼ 400 V

X18 OCV approx. + 80 V

X18 OCV approx. + 40 V

24

Control card A001 layout (Master / Mastertig 2800/3500)

Closed

Open

X10X11

X20

X10X11

X17

X16

X15

X2 X3

R33 Maximum current
R53 MMA ignition current
R72 Minimum current
R75 Inverter frequency
R93 Set value min. (TIG)

X8 X4X5

X8 X4X5

R70

R75

3
.

1
5
A
T

X15

X16

3
.

1
5
A
T

R53

R48

R93R33

X18

X2 X3

X17

R47

X18

R72

R98

R49

X14

X14
X13

X13
X12

X12

X1

X1

X18 MMA

X18 Scratch-TIG

X15 Net voltage 3∼ 400 V

X15 Net voltage 3∼ 460 V

X16 Net voltage 3∼ 460 V

X16 Net voltage 3∼ 400 V

X17 OCV approx. + 80 V

X17 OCV approx. + 40 V

MSD 1-meter unit layout (Master / Mastertig 2800/3500)

R3 Set value current minimum
R4 Set value current maximum

X4

R4

X1

X3

R6R5R3

R5 Voltage
R6 Current

X3 Short circuit loop must be disconnected in

Mastertig 2800 / 3500-power sources

X4 Machine size coding

(Master and Mastertig 2800 / 3500)

25

Control card A002 layout (Master / Mastertig 1500/2200)

JUMPERS

When a jumper is disconnected:

X12 Tacking automatics goes off

X13 Downslope time becomes non-linear, downslope times

X12………….X19

X22

become longer with low currents

X14 Postgas becomes independent from set value, and adjustable
linearly adjustable between 0 - 120s

X2

F1 0,63 AT

X4 X3

X7

X

1

1

R43 Spark voltage adjustment

X1

X20 X21

X10

R43

X15 Downslope will go all the way to the minimum, and won´t be
cut-off at 15 % level of the welding current

X16 Contact ignition current changes 40A -> 25A

X17 Minilog-functions enabled

X18 Empty

X19 Current rise-up speed maximum

X22 ALWAYS KEEP CONNECTED!!

Control card A002 layout (Master / Mastertig 2800/3500)

X1

X3
X4

X5

JUMPERS

When a jumper is disconnected :

X12 Tacking automatics is off

X13 Downslope time is non-linear, downslope times become longer

with low currents

X12…….X19

X21 X20

F1 0,63 AT

X
2

X14 Postgas becomes independent from set value, and adjustable
linearly adjustable between 0 - 120s

X15 Downslope will go all the way to the minimum, and won´t be cut­off at 15 % level of the welding current

X16 Contact ignition current changes 40A -> 25A

X17 Minilog-functions enabled

X18 Empty

X19 Current rise-up speed maximum

26

Control card A004 layout (Master / Mastertig 2800/3500)

X6

F1 1,6AT

R13

R1

X5

X
1

X4

Control card A001 functional testing

Control card power supply ?
(2 x 13 Vac)

X2

Temperature watch PTC ?

X15

X2

X15

R1 Power (Spark)
R13 Voltage (Spark)

X16

X17

R70
R75

A

5

1

T

X20

X11

X10X11

X10

IGBT gate pulses

X8 X4X5

X8 X4X5

.

3

Set value information ?

Control card A001 develops the IGBT gate pulses. If the power supply part is OK, the
fuses are intact, the temperature watch PTCs are OK and correct set value info is received
from the potentiometer, then the gate pulses should be seen on connectors X10 and X11.
When the machine is idling, one must note that it is actually running intermittently.

X3

X16

X18

X17

X3

R93R33

R47

R48

R53

.

3

A

5

1

T

X18

X1

R72

R98

X12

X13

X14

X12

X13

X14

R49

X1

27

Control card A002 functional testing

1 Current set value to power source (0,5…5 Vdc)

2 Current set value to power source (0,5…5 Vdc)

3GND

4GND

5GND

6GND

7

8 Output voltage from power source

(OCV on MMA 75 Vdc)

9

10

11

12

13 MMA/TIG-selection (TIG = 4,5 Vdc, MMA = 0 V)

14 26 Vac from power source

15 26 Vac from power source

16 16 Vdc from power source

The control card A002 uses the 24 Vac to control the solenoid valve and spark ignition, and
transforms the + 16 V voltage to + 5 V for control electronics.

Control card A002 alters the signal taken from control card A001´s (pin 1) set value circuit
according to the adjustments of the operating panel (pin2). It also controls the spark ignition and
solenoid valve.

The power source is controlled by the signal from flat cable´s pin 2 and changes in the operating
panel´s adjustments affect signal in pin 2. On TIG the pin 2 has voltage only when the start is
active and the machine is loaded.
Examples of the voltages on flatcable´s pins 1 and 2:

A=Pin 2 voltage
Pulse ratio approx. 50 %, pause current 40 % and cycle time 1,5 s (0,7 Hz)

B=Pin 1 voltage
Set value information from control card A001´s set value circuit

28

A=Pin 2 voltage
Pulse ratio approx. 10 %, pause current 40 % and cycle time 1,5
s (0,7 Hz)

B= Pin 1 voltage
Set value information from control card A001´s set value circuit

A= Pin 2 voltage
Pulse ratio approx. 50 %, pause current 40 % and cycle time
approx. 0,2 s (50Hz)

B= Pin 1 voltage
Set value information from control card A001´s set value circuit

A= Pin 2 voltage
Pulse ratio approx. 50 %, pause current min. and cycle time
approx. 0,2 s (50Hz)

B= Pin 1 voltage
Set value information from control card A001´s set value
circuit

29

Control card A004 functional testing (Mastertig 2800/3500)

5/1 24 Vac

5/2 Spark generator on/off

5/3 Start switch detection

X6/3 (A004) GND

Mastertig 2800/3500 control card A004 generates the ignition spark for TIG and it also reads
the torchswitch states. The torch switch is separated from other electronics on the
transformer, because the voltage inducted to the switch lines is almost full spark voltage
(approx. 10 kV).

The torch switch state is measured by the connector X5/3, according to these voltage limits:

Measured between X5/3 and ground

Torch switch open Torch switch closed

After closing the torch switch the power stage will start and the output voltage will rise.
Power for the ignition spark is taken from the power source´s output voltage, from which a
spark of approx. 10 kV is developed. The spark generator is started via connector X5/2.

Measured between connectors X5/1
and X5/2

Ignition spark off Ignition spark on

30

Notes

31