Kemppi mastertig acdc 1600, mastertig acdc 2500, mastertig acdc 3500w, mastertig acdc 2500w Service Manual

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

MAINS SUPPLY

CAPACITORS

. DANGEROUS DC VOLTAGE STILL EXISTS EVEN AFTER REMOVAL OF

. WAIT AT LEAST TWO MINUTES (RECOMMENDED DISCHARGE TIME FOR

) 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.

TECHNICAL SERVICE MANUAL FOR MASTERTIG ACDC

TROUBLESHOOTING CHART

PROBLEM CAUSE REMEDY

The MASTERTIG ACDC won’t start
at all. Internal water cooler not
operational

The signal lamps of machine are not
switched on and LEDs are not on in
the function panel.

When the machine is switched on
the cooling fan continuously rotates
and the function panel does not
work, the LED’s are not on.

Some functions from the panel are
not working.

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

Blown fuse(s) in mains supply line *).

Faulty main supply cable.

Faulty main switch S001.

Malfunctioning auxiliary transformer
T002 or loose connection.

Faulty EMC filter card Z002.

Broken function panel or loose
connection between panel and PCB
A002.

The machine is connected to wrong
supply voltage.

Check all three supply voltage
phases so that the fuses are not
blown, change if needed.

Check/repair faulty main supply
cable.

Check the main supply voltage
before and after main switch, change
switch if needed.

Check the transformers supply and 0
V lines, change T002 if needed.

Check the mains supply line voltage
from Z002. Change PCB if need.

Check the flat cables and connectors
from panel and A002, X1 and X2.
Change the function panel if needed.

NOTE! IF SOME FUNCTIONS OF PANEL
ARE MISSING
PROPERLY CHANGE THE PANEL

MEMBRANE

Unplug the machine from the mains
supply and select the correct voltage
from the voltage change-over switch
which is located under the function
panel.

, OR IT IS NOT WORKING

Short breaks in the welding arc and
over/under/wrong supply voltage
LED is on during these breaks

*) Main supply line fuse(s) burned.

Err 1 message in the main display.

Overvoltage in mains supply line. Check the mains supply line. The

Faulty main supply cable.

Short circuit in primary part of the
machine.

Short circuit in secondary part of the
machine.

Secondary voltage of machine has
been over 90 volts more than 4
seconds.

approx. voltage limits are mentioned
in TABLE

Check/repair faulty main supply
cable.

Check/change the main switch,
primary rectifier, primary IGBT unit
and inverse parallel diode.

Check/change the secondary rectifier
unit (diode blocks) and secondary
IGBT unit. See also

TROUBLESHOOTING FOR
POWER SEMICONDUCTORS.

IGBT V47, which is located in control
card A003 PICTURE
Check and change the pcb or IGBT.

4.

1., is faulty.

TECHNICAL SERVICE MANUAL FOR MASTERTIG ACDC

TROUBLESHOOTING CHART

PROBLEM CAUSE REMEDY

The cooling unit is not operational
or H001 light is on.

The water doesn’t circulate by switch
SW302.

Water doesn’t return back to the
tank.

Blown fuse F002 2A.

Broken or faulty auxiliary­transformer T005.

Broken pressure switch S002.

Pressure switch set value is
unsuitable for the

TIG torch which

is in use (other than original Kemppi
torch).

Air bubbles in the system.

Check and change the fuse if
needed.

Check first the supply voltage of
transformer from Z004, connector
1=230V, 2=400, and 3=460V. Then
check the secondary voltage of
transformer, check it from terminal
block XW301 between 4 an 5 the
voltage is c. 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:

START PRESSING TEST SWITCH

I

SW302 AND ADJUST THE ADJUSTMENT

SCREW

(SEE PICTURE 3.) FOR

PRESSURE, IN SUCH WAY THAT THE
SIGNAL LAMP
SWITCHED OFF

RELEASE SWITCH SW302 AND WAIT

II

FOR APPR
SIGNAL LAMP

STILL CHECK BY WELDING FOR

III

APPROX
MORE DISTURBANCES

H001 IS ONLY JUST

.

. 10 S AND CHECK THAT

H001 IS NOT FLASHING.

. 20 S THAT THERE ARE NO

.

The solenoid valve Y001 is not
operating // stuck open

Leakages in the cooling system.

Pump motor 5µ starting capacitor
C004 is faulty.

Broken or faulty PCB A005 .

Faulty solenoid valve Y001 or
broken PCB A002.

Blow compressed air into tank,
closing the filling hole by hands is
enough.

Check/repair the connection of
cooling system connector by
connector. Repair the system if
needed.

Check and change the capacitor if
needed.

Change/repair PCB A005.

Check the 24 VDC from A002
connector X9 between pins 1and 2.
If it is ok, change the solenoid valve.

TECHNICAL SERVICE MANUAL FOR MASTERTIG ACDC

TROUBLESHOOTING CHART

PROBLEM CAUSE REMEDY

Remote control unit is not operating
properly.

Machine is overheating. Signal lamp
for thermal protection is on even if
the duty-cycle time has not been
exceeded.

There are occasional disturbances
during welding, set value is not
stable or arc is intermittent.

Arc is stopping intermittently.

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.

Faulty cooling fan(s) or PCB A002.

Loose connector.

Remote control unit is faulty

Faulty start switch in

Broken/faulty
wire(s) in

TIG torch.

TIG torch.

TIG torch, loose start

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.

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.

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.

Welding quality is bad in all methods:

• arc is not stable

• bad arc start

• not enough arc voltage

• lack of power

Faulty Reed relay, K001.

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 it by opening the connector
X009, change reed relay if needed.

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.

TECHNICAL SERVICE MANUAL FOR MASTERTIG ACDC

TROUBLESHOOTING CHART

PROBLEM CAUSE REMEDY

Porosity in the weld joint. Shield gas flow is not correct,

No HF ignition Faulty control card A004.

Welding characteristics are bad
when welding method is AC TIG.

Positive or negative half cycle is
missing, or both are missing.

Machine is creating high pitched or
rattling sound.

leakage in the gas hose or faulty
solenoid valve.

Broken HF-transformer T003.

Additional pulse to ignite the positive
half cycle is missing.

Faulty control card A002 or A003.

Faulty IGBT in primary or secondary
inverter.

Faulty gate IGBT connection in
control card A002 or A003.

Check the gas flow; adjust correct
flow according welding parameters
or repair faulty component in gas
flow system.

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
change the HF-transformer T003.

Check the function of control card
A003. The pulse circuit driving
component is small IGBT V47.
Check and change the IGBT if
needed.

Check that control of selecting
welding method is working from the
PCB A003, see PICTURE 1.

Check according following text;

Primary inverter is VG 101.

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.

If security code is in use and panel is
locked.

Maximum positive or negative
current adjustment is incorrect.

See also PICTURE

Wrong security code. The locked panel can be unlocked at

Wrong/changed adjustment in
control card A002.

an authorised KEMPPI service repair
shop with a special code . The
unlock code is available only in
these places.

Maximum positive and negative
current can adjust from A002, see
also PICTURE 2.

4.

TECHNICAL SERVICE MANUAL FOR MASTERTIG ACDC

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

J02

DOWN SLOPE

J03

TIG ANTIFREEZE

J04
AC

BALANCE

J05

TACK WELDING

J06

DOWN SLOPE CUT OFF

LEVEL

J07

OPEN CIRCUIT VOLTAGE

J08

CHINA LOGIC”

“

TIG WELDING IN 4T

UP SLOPE TIME DEPENDS ON
SET VALUE OF CURRENT

DOWN SLOPE TIME DEPENDS
ON SET VALUE OF CURRENT

UP SLOPE TIME IS INDEPENDENT OF SET
VALUE OF CURRENT

DOWN SLOPE TIME IS INDEPENDENT OF
SET VALUE OF CURRENT

TIG ANTIFREEZE IS ON TIG ANTIFREEZE IS OFF

MANUAL
CONTROL IS IN USE

TACK WELDING IS AUTOMATIC DOWN SLOPE FUNCTIONS IMMEDIATELY

DOWN SLOPE CUT OFF LEVEL
IS MINIMUM CURRENT

OPEN CIRCUIT VOLTAGE
IS

POSSIBILITY TO PRESET

STARTING CURRENT
WELDING CURRENT AND
END CURRENT

70 V

AC BALANCE

SMART BALANCE FUNCTION IS IN USE,
SCALE OF PANEL IS IN USE

DOWN SLOPE CUT OFF LEVEL IS
OF SET VALUE

OPEN CIRCUIT VOLTAGE IS C. 39.5 V

NORMAL

4T FUNCTION

20 %

,

J09

Inverter Frequency

J10
2T Hot/ soft start

J11
2T Hot/ soft start time
setting
J12
2T Downslope

J13-15

JO16

POSITIVE START CYCLE OF

AC-TIG
JO17

IGNITION PULSE

MMA

NVERTER FREQUENCY IS 18

I

KHZ IN THE WHOLE CURRENT
RANGE

OT/ SOFT START IS IN USE

H

TIG 2T LOGIC

WITH

OT/ SOFT START TIME IN 2T

H

LOGIC. ADJUSTMENT RANGE
IS

0,0-9,9 SECONDS

N 2T THE DOWNSLOPE

I

DOESN

´T END WITH A SHORT

OR A LONG PULL
WELDING CURRENT CAN BE
TAKEN UP AND DOWN WITH A
SHORT PULL ON THE TRIGGER

N

OT IN USE

ADJUSTMENT FOR LENGTH OF
POSITIVE START CYCLE
FACTOR 0.0 2.0

ADJUSTMENT OF
IGNITION PULSE (0,0-2,0)

, SO THE

,

MMA

INVERTER FREQUENCY IS 18 KHZ/ 36

KHZ IN MMA!

IN 2T THE WELDING IS ENDED DURING

DOWNSLOPE WITH A SHORT PULL ON
THE TRIGGGER

FACTORY SETTING IS 1

FACTORY SETTING IS 1

TECHNICAL SERVICE MANUAL FOR MASTERTIG ACDC

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.

TECHNICAL SERVICE MANUAL FOR MASTERTIG ACDC

TABLE 1. FUNCTION SIGNALS CONNECTORS X1 AND X2 OF PCB A001

PIN NUMBER DESCRIPTION

X1

X1/1
X1/2
X1/3
X1/4
X1/5
X1/6
X1/7
X1/8
X1/9
X1/10
X1/11
X1/12
X1/13
X1/14
X1/15
X1/16

X2

X2/1
X2/2
X2/3
X2/4
X2/5
X2/6
X2/7
X2/8
X2/9
X2/10
X2/11
X2/12
X2/13
X2/14
X2/15
X2/16

IDENTIFICATION OF THE SIZE OF THE MACHINE

SET VALUE FROM THE REMOTE CONTROL UNIT

SELECTION OF METHOD FROM THE REMOTE CONTROL UNIT
THERMAL PROTECTION(PTC)

NOT IN USE

CONTROL OF COOLING FANS
CONTROL OF MAINS SUPPLY VOLTAGE FROM T002 SECONDARY WINDING

NOT IN USE
WELDING CURRENT ; POSITIVE HALF-CYCLES OF DC+ OR AC
WELDING CURRENT ; NEGATIVE HALF-CYCLES OF DC- OR AC
WELDING VOLTAGE ; NEGATIVE HALF-CYCLES OF DC- OR AC
WELDING VOLTAGE ; POSITIVE HALF-CYCLES OF DC+ OR AC

CONTROL OF MAINS VOLTAGE

OVER CURRENT

SWITCH OF TIG TORCH
ADDITIONAL AC PULSE FOR TIG

SOLENOID VALVE

CONTROL OF TIG SPARK

NOT IN USE

PWM

POSSIBLE

CONTROL OF SECONDARY IGBT

C

ONTROL OF SECONDARY IGBT

+16 V
+15 V
+5 V
+5 V
GND
GND

START OF COOLING UNIT

STOP OF COOLING UNIT

NOT IN USE

NOT IN USE

TECHNICAL SERVICE MANUAL FOR MASTERTIG ACDC

TABLE 2. CONNECTOR XW101 IN MASTERTIG ACDC

PIN NUMBER SIGNAL VALUE DESCRIPTION

A

B

C
D

3.5 VAC start not active
0 V start is active

3.5 VAC start not active
0 V start is active

--

--

Torch start switch

Torch start switch

TABLE 3. CONNECTOR XW102 IN MASTERTIG ACDC

PIN NUMBER SIGNAL VALUE DESCRIPTION

A
B

C

D
E

F
G
H
I

J

-­30 VAC Operating voltage for external

equipment, fuse 0.8 A

30 VAC Operating voltage for external

equipment, fuse 0.8 A

-­+5 VDC Voltage reference of remote control

(upper end of the potentiometers)

0 V GND (lower end of potentiometers)

-­0 - +5 VDC Set value for power source
+2 VDC=
+5 VDC=MMA

--

TIG

Selection of characteristic TIG/MMA curve

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
400 VAC
460 VAC

175 VAC 270 VAC
300 VAC 460 VAC
340 VAC 530 VAC

MASTERTIG ACDC 3500

400 VAC

365 VAC 460 VAC

TECHNICAL SERVICE MANUAL FOR MASTERTIG ACDC

V

X

X

PICTURE 1. LEDS IN PCB A003

X7

R77

X1

X8

H2

H1

MASTERTIG AC/DC A003

T1

T2

T3

47

10

X5

X3

R57

X11

4

L1

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

X12

TECHNICAL SERVICE MANUAL FOR MASTERTIG ACDC

0

X

0

X8

PICTURE 2. TRIMMERS IN PCB A002

X1

X2

X1

T1

MASTERTIG AC/DC A002

N4 N1 N2

R44

F2

F4

X22

X7

X6

X5

X2

X14

X4X3

TRIMMERS

R44 ADJUSTMENT FOR BASIC FREQUENCY
R118 ADJUSTMENT FOR DC- MAX CURRENT
R119 ADJUSTMENT FOR DC+ MAX CURRENT

11

R119

R118

X9

TECHNICAL SERVICE MANUAL FOR MASTERTIG ACDC

PICTURE 3. PRESSURE ADJUSTMENT SCREW

*

* Adjustment screw for adjusting correct set value for pressure

PICTURE 4. MAIN CIRCUIT OF MASTERTIG ACDC

L001

G001

S001

VG101

R001

T001

G002

T003

X005

( TIG )

( MMA )

X004

VG201

VG202

TECHNICAL SERVICE MANUAL FOR MASTERTIG ACDC

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.

MASTERTIG AC/DC 1600

A

A

A

Order no. Part Description Pc.

4295710
4277540
4280540
4283150
9772516
9772551
4281530
4286000
9750126
4280860
3139530
4290890
4280880
3140270
9777115
9544213
4260200
9761221
2067620
9777825
2067590
9777537
9770105
9770116
4292780
9771530
9771530
4262810
9563002
9755615
4281560
4282130
4282300
3134270
4286030
9377205
9370182
2067100
2067120
4280870
2067130
3139460
4296190
2067260
2067270
3139520
3133020
4280560
3140350
9770456
9770457
9770458
9770460
9770462
9770464

002
003

004
C001
F001

GA001
VG101
VG102
G001
G002
VG201
G003
L001
L003
M001
R001
S001
T001
T002
T003
T004
XW101
XW102
X003
X004
X005
X006
Y001
ZC213
Z001
Z002
001
002
003
004
005
006
007
008
009
010
011
012
013
014
015
016

CONTROL CARD A002 MASTERTIG AC/DC 1
CONTROL CARD MAS.TIG AC/DC A003 1
CONTROL CARD MAS.TIG AC/DC A004 1
CAPACITOR C001 AC/DC 1
FUSE 0,8A DELAYED 5 X 20 1
FUSE BOX + NUT 1
DIODE CARD 1
SPARE PART IGBT 1
DIODE BRIDGE 1
PRIMARY UNIT 1
SECONDARY UNIT 1
IGBT, SECONDARY AC/DC 1
SECONDARY UNIT G003 MTIG 1600 ACDC 2
PRIMARY CHOKE 1
FERRITE RING 25/15 X 10 1
COOLING FAN MASTER 1500/2200 1
SHUNT RESISTOR MASTER 1500/2200 1
FLIP-FLOP SWITCH WITH PILOT LAMP 1
MAIN TRANSFORMER 1
AUXILIARY TRANSFORM. 1
SPARK TRANSFORMER 1
CURRENT TRANSFORMER 1:250 PRO 1
CONTROL CONNECT. 4 POLES, FEMALE 1
MACHINE SOCKET 1
CONIC COUPLING R 1/4-M 8X1 1
MACHINE SOCKET 50/70 1
MACHINE SOCKET 50/70 1
FLAT CABLE L=175 1
SOLENOID VALVE 1
CAPACITOR 470 UF 1
FILTER CARD 1
MAIN CIRCUIT CARD 1
RUBBER 1
HOSE CONNECTOR R1/8-M12 1
GAS CONNECTOR 1
HOSE CLAMP 1
PLASTIC HOSE 5/8 BLUE 0,25
FOOT 1
HANDLE MTIG 1600/2500 AC/DC 1
HANDLE 1
PROTECTIVE COVER MTIG 1600/2500 AC/DC 1
PLASTIC PIECE 1
STICKER MASTERTIG AC/DC 1
SIDE PLATE LEFT MTIG1600 ACDC 1
SIDE PLATE RIGHT MTIG1600 ACDC 1
COVER MTIG1600 ACDC 1
FOOT F COOL.PROFIL 1
FAST.PC F COOL.PROF. 1
CIRCUIT DIAGRAM MASTERTIG 1600AC/DC 1
PLUG 2 POLES 1
PLUG 3-POLES 1
PLUG 6 POLES 1
PLUG 15 POLES 1
CONTACT , MALE 1
CONTACT, FEMALE 1

27.11.2001/V161601 1027620 C/1916140

MASTERTIG AC/DC 2000

A

A

A

Order no. Part Description Pc.

4295710
4277540
4280540
4283150
9772516
9772551
428086001
428600001
9750126
4299800
4300750
429089001
4280880
4281530
3149440
9777115
9544221
4260200
9760604
2067620
9777825
2067590
9777537
9770105
9770116
4292780
9771530
4262810
9563002
9755615
4281560
4282130
4282300
3134270
4286030
9377205
9370182
2067100
2067120
4280870
2067130
3139460
4296190
206726001
206727001
3139520
3133020
4280560
4280580
3149110
9770458
9770460
9770462
9770464

002

003

004
C001
F001
F001
G001
VG101
VG102
G002
VG201
VG201
G003
GA001
L001
L003
M001
R001
S001
T001
T002
T003
T004
XW101
XW102
X003
X004
X006
Y001
ZC213
Z001
Z002
001
002
003
004
005
006
007
008
009
010
011
012
013
014
015
016
017

CONTROL CARD A002 MASTERTIG AC/DC
CONTROL CARD MAS.TIG AC/DC A003
CONTROL CARD MAS.TIG AC/DC A004
CAPACITOR C001 AC/DC
FUSE 0,8A DELAYED 5 X 20
FUSE BOX + NUT
PRIMARY UNIT G001 MTIG AC/DC 2000
SPARE PART IGBT MASTERTIG AC/DC 2000
DIODE BRIDGE
SECONDARY UNIT G002 MTIG AC/DC 2000
IGBT, SECONDARY 2PCS 2X200A ACDC2000
IGBT, SECONDARY 1 PC 2X400A ACDC2000
SECONDARY UNIT G003 MASTERTIG AC/DC
DIODE CARD
PRIMARY CHOKE MASTERTIG AC/DC 2000
FERRITE RING 25/15 X 10
COOLING FAN MASTER,-TIG MLS
SHUNT RESISTOR MASTER 1500/2200
SWITCH
MAIN TRANSFORMER
AUXILIARY TRANSFORM.
SPARK TRANSFORMER
CURRENT TRANSFORMER 1:250 PRO
CONTROL CONNECT. 4 POLES, FEMALE
MACHINE SOCKET
CONIC COUPLING R 1/4-M 8X1
MACHINE SOCKET 50/70
FLAT CABLE L=175
SOLENOID VALVE
CAPACITOR 470 UF
FILTER CARD
MAIN CIRCUIT CARD
RUBBER
HOSE CONNECTOR R1/8-M12
GAS CONNECTOR
HOSE CLAMP
PLASTIC HOSE 5/8 BLUE
FOOT
HANDLE MTIG 1600/2500 AC/DC
HANDLE
PROTECTIVE COVER MTIG 1600/2500 AC/DC
PLASTIC PIECE
STICKER MASTERTIG AC/DC
SIDE PLATE LEFT MASTERTIG AC/DC 2000
SIDE PLATE RIGHT MASTERTIG AC/DC 2000
COVER MTIG ACDC 1600,2000
FOOT F COOL.PROFIL
FAST.PC F COOL.PROF.
SPRING MASTERTIG AC/DC
CIRCUIT DIAGRAM MASTERTIG 2000 AC/DC
PLUG 6 POLES
PLUG 15 POLES
CONTACT , MALE
CONTACT, FEMALE

13.08.2002/V162001 1029860

1
1
1
1
1
1
1
1
1
1
1
0
4
4
1
6
2
1
1
1
1
1
1
1
1
1
2
1
1
4
1
1
4
1
1
2

0,25

2
2
1
1
2
2
1
1
1

11

4
1
1
2
1
1
1

MASTERTIG AC/DC 2500

A

A

A

Order no. Part Description Pc.

4295710
4277540
4280540
4283150
9755264
9414086
9772516
9772551
4286780
9750126
9750174
2067020
3139440
4281520
4286020
4280570
3137400
9777115
9544213
4260200
976050201
2067930
9760632
9777825
2062420
9777537
9770116
9770105
4292780
9771530
4262810
9563002
4277550
4282080
4282300
3134270
9568913
9377256
9370101
2067100
2067120
4280930
2067130
3139460
4296190
4282960
2067060
2067070
2067080
3133020
4280560
3140360
9770456
9770457
9770458
9770460
9770462
9770464

002

003

004
C001
C003

F001

VG103
VG102
VG101
G001
G002
GA001
VG201
G003
L001
L003
M001
R001
S001
T001
S003
T002
T003
T004
XW101
XW102
X003
X004
X006
Y001
Z001
Z002
001
002
003
004
005
006
007
008
009
010
011
012
013
014
015
016
017

CONTROL CARD A002 MASTERTIG AC/DC 1
CONTROL CARD MAS.TIG AC/DC A003 1
CONTROL CARD MAS.TIG AC/DC A004 1
CAPACITOR C001 AC/DC 1
CAPACITOR 75 UF 1
BOX NUT 1
FUSE 0,8A DELAYED 5 X 20 1
FUSE BOX + NUT 1
SPARE PART IGBT 2 X 200A 1
DIODE BRIDGE 1
RECTIFIER UNIT 1
PRIMARY UNIT MTIG2500 3J ACDC 1
SECONDARY UNIT MTIG 2500 ACDC 1
DIODE CARD 1
IGBT, SECONDARY AC/DC 1
SECONDARY UNIT 2
PRIMARY CHOKE L001/MASTER2850 3J 1
FERRITE RING 25/15 X 10 1
COOLING FAN MASTER 1500/2200 1
SHUNT RESISTOR MASTER 1500/2200 1
MAIN SWITCH K60/12 D22,5 1
MAIN TRANSFORMER 1
V.CHANGE-OVER SW. 1
AUXILIARY TRANSFORM. 1
SPARK TRANSFORMER MASTERTIG 2800/3500 1
CURRENT TRANSFORMER 1:250 PRO 1
MACHINE SOCKET 1
CONTROL CONNECT. 4 POLES, FEMALE 1
CONIC COUPLING R 1/4-M 8X1 1
MACHINE SOCKET 50/70 2
FLAT CABLE L=175 1
SOLENOID VALVE 1
MAIN CIRCUIT CARD MTIG AC/DC 2500 1
FILTER CARD 1
RUBBER 1
HOSE CONNECTOR R1/8-M12 1
HOSE CONNECTOR R1/8-6ML 1
HOSE CLAMP 1
PVC HOSE 0,25
FOOT 1
HANDLE MTIG 1600/2500 AC/DC 1
HANDLE MTIG 2500 ACDC 1
PROTECTIVE COVER MTIG 1600/2500 AC/DC 1
PLASTIC PIECE 1
STICKER MASTERTIG AC/DC 1
VOLTAGE STICKER ACDC 1
SIDE PLATE LEFT MTIG2500 ACDC 1
SIDE PLATE RIGHT MTIG2500 ACDC 1
COVER MTIG2500,3500W ACDC 1
FOOT F COOL.PROFIL 1
FAST.PC F COOL.PROF. 1
CIRCUIT DIAGRAM MTIG 2500 AC/DC 1
PLUG 2 POLES 1
PLUG 3-POLES 1
PLUG 6 POLES 1
PLUG 15 POLES 1
CONTACT , MALE 1
CONTACT, FEMALE 1

27.11.2001/V162501 2068280 C/1916150

MASTERTIG 2500W ACDC

A

A

A

A

Order no. Part Description Pc.

4295710
4277540
4280540
4279500
4283150
9414086
9755264
9755223
9772516
9772551
9772520
9772551
2067020
4286780
9750126
9750174
3139440
4281520
4286020
4280570
9775731
9775729
4249080
3140840
9777115
9544213
3138320
9544306
9544305
9540415
9540411
4260200
9761375
9761323
976050201
9761622
9760632
2067930
9777825
2062420
9777537
3141530
9770116
9770105
4292780
9771530
4262810
4292790
9563002
4277550
4282080
4278020
4282300
3134270
9568911
9377256
9370101
2067100
2067120
4280930

002

003

004

005
C001
C003
C003
C004
F001
F001
F002
F002
G001
VG103
VG102
VG101
G002
GA001
VG201
G003
H001
H002
K001
L001
L003
M001
M003
M003
M003
M003
M003
R001
SW301
SW302
S001
S002
S003
T001
T002
T003
T004
T005
XW101
XW102
X003
X004
X006
X007
Y001
Z001
Z002
Z004
001
002
003
004
005
006
007
008

CONTROL CARD A002 MASTERTIG AC/DC 1
CONTROL CARD MAS.TIG AC/DC A003 1
CONTROL CARD MAS.TIG AC/DC A004 1
CONTROL CARD A002 KWELD 4000W 1
CAPACITOR C001 AC/DC 1
BOX NUT 1
CAPACITOR 75 UF 1
CAPACITOR 8UF/450V AC 1
FUSE 0,8A DELAYED 5 X 20 1
FUSE BOX + NUT 1
FUSE DELAYED 2A 5X20 1
FUSE BOX + NUT 1
PRIMARY UNIT MTIG2500 3J ACDC 1
SPARE PART IGBT 2 X 200A 1
DIODE BRIDGE 1
RECTIFIER UNIT 1
SECONDARY UNIT MTIG 2500 ACDC 1
DIODE CARD 1
IGBT, SECONDARY AC/DC 1
SECONDARY UNIT 2
SIGNAL LAMP RED 1
SIGNAL LAMP YELLOW 1
REED RELAY 1
PRIMARY CHOKE 1
FERRITE RING 25/15 X 10 1
COOLING FAN MASTER 1500/2200 1
PUMP-MOTOR COMB. SIMACO 1
COOLING FAN WING SIMACO 1
COOLING FAN WING SPECK 1
REPAIR SET FOR PUMP SIMACO 1
REPAIR SET FOR PUMP SPECK 1
SHUNT RESISTOR MASTER 1500/2200 1
LEVER SWITCH 1
CHANGE OVER SWITCH 1
MAIN SWITCH K60/12 D22,5 1
PRESSURE SWITCH 1
V.CHANGE-OVER SW. 1
MAIN TRANSFORMER 1
AUXILIARY TRANSFORM. 1
SPARK TRANSFORMER MASTERTIG 2800/3500 1
CURRENT TRANSFORMER 1:250 PRO 1
TRANSFORMER 1
MACHINE SOCKET 1
CONTROL CONNECT. 4 POLES, FEMALE 1
CONIC COUPLING R 1/4-M 8X1 1
MACHINE SOCKET 50/70 2
FLAT CABLE L=175 1
CURRENT/WATER CONN. R3/8"/R1/4" 1
SOLENOID VALVE 1
MAIN CIRCUIT CARD MTIG AC/DC 2500 1
FILTER CARD 1
FILTER CARD 1
RUBBER 1
HOSE CONNECTOR R1/8-M12 1
HOSE CONNECTOR R1/8-5ML 1
HOSE CLAMP 1
PVC HOSE 0,25
FOOT 1
HANDLE MTIG 1600/2500 AC/DC 1
HANDLE MTIG 2500 ACDC 1

27.11.2001/V162506 2068340 D/1916160

MASTERTIG 2500W ACDC

Order no. Part Description Pc.

2067130
3139460
4296190
4282950
4282960
2067060
2067070
2067080
4241513
9592126
4237831
9761302
9581005
2069370
2067360
3133020
4280560
4257910
3140360
3140370
9770456
9770457
9770458
9770460
9770462
9770464

009
010
011
012
013
014
015
016
017
018
019
020
021
022
023
024
025
026

PROTECTIVE COVER MTIG 1600/2500 AC/DC 1
PLASTIC PIECE 1
STICKER MASTERTIG AC/DC 1
STICKER GAS/WATER ACDC 1
VOLTAGE STICKER ACDC 1
SIDE PLATE LEFT MTIG2500 ACDC 1
SIDE PLATE RIGHT MTIG2500 ACDC 1
COVER MTIG2500,3500W ACDC 1
CONNECTION CABLE 1
WATER TANK 1
GAS HOSE D6/R1/8-1.7M 1
PROTECTION SWITCHES'LEVER 1
HEAT EXCHANGER 220X225 SIMACO 1
SIDE PLATE LEFT MTIG2500W,3500WACDC 1
SIDE PLATE RIGHT MTIG2500W,3500WACDC 1
FOOT F COOL.PROFIL 1
FAST.PC F COOL.PROF. 1
CONIC HOSE COUPLING R3/8-1/2 KL 1
CIRCUIT DIAGRAM MTIG 2500 AC/DC 1
CIRCUIT DIAGRAM MTIG-W AC/DC 1
PLUG 2 POLES 1
PLUG 3-POLES 1
PLUG 6 POLES 1
PLUG 15 POLES 1
CONTACT , MALE 1
CONTACT, FEMALE 1

27.11.2001/V162506 2068340 D/1916160

MASTERTIG ACDC 3500W

A

A

A

A

Order no. Part Description Pc.

4295710
4277540
4280540
4279500
4283150
9755268
9755223
9772516
9772520
9772551
2067020
4286780
9750126
9750174
2069290
4288750
3142530
3142560
4281520
9755118
9753592
9753161
4268440
9775731
9775729
4249080
3137401
9777115
9777121
4288500
9544214
3138320
9544306
9544305
9540415
9540411
4260200
9761375
9761323
976050201
9761622
2069320
4288330
9777825
2062420
9777537
3143110
9770105
9770116
9771530
4219610
9771530
4262810
4292790
9563002
4288230
4288240
4282300
9480207
4282030

002

003

004

005
C001
C002
C004
F001
F002
F002
G001
VG101
VG102
VG103
G002
VG201
G003
G005
GA001
C101
R101
R102
RG003
H001
H002
K001
L001
L003
L005
L006
M001
M003
M003
M003
M003
M003
R001
SW301
SW302
S001
S002
T001
RT101
T002
T003
T004
T005
XW101
XW102
X003
X004
X005
X006
X007
Y001
Z001
Z002
001
002
003

CONTROL CARD A002 MASTERTIG AC/DC 1
CONTROL CARD MAS.TIG AC/DC A003 1
CONTROL CARD MAS.TIG AC/DC A004 1
CONTROL CARD A002 KWELD 4000W 1
CAPACITOR C001 AC/DC 1
SMOOTHING CAPASITOR 25UF/700VDC 1
CAPACITOR 8UF/450V AC 1
FUSE 0,8A DELAYED 5 X 20 1
FUSE DELAYED 2A 5X20 2
FUSE BOX + NUT 2
PRIMARY UNIT MTIG2500 3J ACDC 1
SPARE PART IGBT 2 X 200A 1
DIODE BRIDGE 1
RECTIFIER UNIT 1
SECONDARY UNIT MTIG 3500W ACDC 1
IGBT, SECONDARY MTIG 3500W ACDC 2
SECONDARY UNIT MTIG 3500W ACDC 2
SECONDARY UNIT MTIG 3500W ACDC 1
DIODE CARD 8
CAPACITOR 4.7 NF/1000V 1
VARISTOR 250V 20 MM 1
RESISTOR 100R 5W 1
PTC RESISTOR +90 C 3
SIGNAL LAMP RED 1
SIGNAL LAMP YELLOW 1
REED RELAY 1
PRIMARY CHOKE MTIG 3500W ACDC 1
FERRITE RING 25/15 X 10 4
FERRITE CORE U57/28/16 2
FERRITE CHOKE 1
COOLING FAN MASTER 2800/3500 1
PUMP-MOTOR COMB. SIMACO 1
COOLING FAN WING SIMACO 1
COOLING FAN WING SPECK 1
REPAIR SET FOR PUMP SIMACO 1
REPAIR SET FOR PUMP SPECK 1
SHUNT RESISTOR MASTER 1500/2200 1
LEVER SWITCH 1
CHANGE OVER SWITCH 1
MAIN SWITCH K60/12 D22,5 1
PRESSURE SWITCH 1
MAIN TRANSFORMER MTIG 3500W ACDC 1
PTC RESISTOR +140 C 1
AUXILIARY TRANSFORM. 1
SPARK TRANSFORMER MASTERTIG 2800/3500 1
CURRENT TRANSFORMER 1:250 PRO 1
AUXIL. TRANSFORMER MTIG 3500W ACDC 1
CONTROL CONNECT. 4 POLES, FEMALE 1
MACHINE SOCKET 1
MACHINE SOCKET 50/70 1
CONIC HOSE COUPLING R1/4-6ML 2
MACHINE SOCKET 50/70 1
FLAT CABLE L=175 1
CURRENT/WATER CONN. R3/8"/R1/4" 1
SOLENOID VALVE 1
MAIN CIRCUIT CARD MTIG 3500W ACDC 1
PRIMARY FILTER CARD MTIG3500W ACDC 1
RUBBER 8
CUP SPRING 12.5X6.2X0.7 32
STRAINING BEAM 4

27.11.2001/V163505 2069530 B/1916180

MASTERTIG ACDC 3500W

Order no. Part Description Pc.

9433068
3134270
9568911
9377200
9370182
2067100
2067120
4280930
2067130
3139460
4296190
4282950
2069050
2069060
2067080
2069370
2067360
9592126
9581005
4257910
9761302
3130180
4280560
9373216
9373215
9377130
3142870
3140370
9770450
9770452
9770454
9770456
9770457
9770458
9770460
9770462
9770464

004
005
005
006
007
008
009
010
011
012
013
014
015
016
017
018
019
020
021
022
023
024
025
026
027
028

SLOT-HEADED SCREW M6X25 8
HOSE CONNECTOR R1/8-M12 1
HOSE CONNECTOR R1/8-5ML 1
HOSE CLAMP 1
PLASTIC HOSE 5/8 BLUE 0,25
FOOT 4
HANDLE MTIG 1600/2500 AC/DC 2
HANDLE MTIG 2500 ACDC 1
PROTECTIVE COVER MTIG 1600/2500 AC/DC 1
PLASTIC PIECE 3
STICKER MASTERTIG AC/DC 2
STICKER GAS/WATER ACDC 1
SIDE PLATE LEFT MTIG 3500W ACDC 1
SIDE PLATE RIGHT MTIG 3500W ACDC 1
COVER MTIG2500,3500W ACDC 1
SIDE PLATE LEFT MTIG2500W,3500WACDC 1
SIDE PLATE RIGHT MTIG2500W,3500WACDC 1
WATER TANK 1
HEAT EXCHANGER 220X225 SIMACO 1
CONIC HOSE COUPLING R3/8-1/2 KL 1
PROTECTION SWITCHES'LEVER 2
FOOT T/6 11
FAST.PC F COOL.PROF. 2
RUBBER HOSE 13 MM 2,46
RUBBER HOSE 10/17 MM 0,68
HOSE CLAMP 13-20 MM 8
CIRCUIT DIAGRAM MTIG 3500W AC/DC 1
CIRCUIT DIAGRAM MTIG-W AC/DC 1
FEMALE CONTACT BODY 2 POLES 1
FEMALE CONTACT BODY 6 POLES 3
FEMALE CONTACT BODY 15 POLES 1
PLUG 2 POLES 1
PLUG 3-POLES 3
PLUG 6 POLES 8
PLUG 15 POLES 2
CONTACT , MALE 25
CONTACT, FEMALE 73

27.11.2001/V163505 2069530 B/1916180