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Table of Contents
- 1 Introduction / General Maintenance of Mastertig Acdc
- 2 Troubleshooting
- 3 Troubleshooting Chart
- 4 Table of Jumpers, Extra Functions
- 5 Selection of Remote Control Unit
- 6 Calibration of the Panel
- 7 Function Signals Connectors X1 and X2 of Pcb A001
- 8 Pin Number
- 9 Connector Xw101 in Mastertig Acdc
- 10 Connector Xw102 in Mastertig Acdc
- 11 Over and under Voltage Limits
- 12 Leds in Pcb A003
- 13 Trimmers in Pcb A002
- 14 Pressure Adjustment Screw
- 15 Main Circuit of Mastertig Acdc
- 16 Changing the Set of Diodes in Secondary Rectifier of Mastertig Acdc
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Table of Contents
Troubleshooting
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Summary of Contents for Kemppi mastertig acdc 1600
- Page 1 TECHNICAL SERVICE MANUAL FOR MASTERTIG ACDC MACHINES...
- Page 2 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.
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Page 3: Troubleshooting Chart
TECHNICAL SERVICE MANUAL FOR MASTERTIG ACDC 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. - Page 4 5V. Pressure switch set value is Adjust the pressure set value from unsuitable for the torch which the adjustment screw, of pressure is in use (other than original Kemppi switch according following torch). instructions: TART PRESSING TEST SWITCH SW302...
- Page 5 TECHNICAL SERVICE MANUAL FOR MASTERTIG ACDC TROUBLESHOOTING CHART PROBLEM CAUSE REMEDY 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.
- Page 6 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.
- Page 7 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;...
- Page 8 TECHNICAL SERVICE MANUAL FOR MASTERTIG ACDC SELECTION OF REMOTE CONTROL UNIT 1. Turn off the machine. 2. Press the key and at the same time turn the machine on; the display REMOTE 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).
- Page 9 TECHNICAL SERVICE MANUAL FOR MASTERTIG ACDC TABLE 1. FUNCTION SIGNALS CONNECTORS X1 AND X2 OF PCB A001 PIN NUMBER DESCRIPTION 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 X1/5...
- Page 10 Selection of characteristic curve +5 VDC= TABLE 4. OVER AND UNDER VOLTAGE LIMITS, ( OCV) WHEN SUPPLY VOLTAGE LOWER LIMIT UPPER LIMIT MASTERTIG ACDC 1600 165 VAC 270 VAC 230 VAC MASTERTIG ACDC 2500 230 VAC 175 VAC 270 VAC 400 VAC...
- Page 11 TECHNICAL SERVICE MANUAL FOR MASTERTIG ACDC PICTURE 1. LEDS IN PCB A003 MASTERTIG AC/DC A003 LEDs, are on when machine is generating OCV IS ON WHEN THE MACHINE IS IN TIG OR MMA DC + IS ON WHEN THE MACHINE IS IN TIG OR MMA...
- Page 12 TECHNICAL SERVICE MANUAL FOR MASTERTIG ACDC PICTURE 2. TRIMMERS IN PCB A002 MASTERTIG AC/DC A002 R119 R118 TRIMMERS ADJUSTMENT FOR BASIC FREQUENCY R118 ADJUSTMENT FOR MAX CURRENT R119 ADJUSTMENT FOR MAX CURRENT...
- Page 13 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 X005 ( TIG ) T001 T003 ( MMA ) X004 VG201 G002...
- Page 14 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.
- Page 18 27.11.2001/V161601 1027620 C/1916140 MASTERTIG AC/DC 1600 Order no. Part Description 4295710 A002 CONTROL CARD A002 MASTERTIG AC/DC 4277540 A003 CONTROL CARD MAS.TIG AC/DC A003 4280540 A004 CONTROL CARD MAS.TIG AC/DC A004 4283150 C001 CAPACITOR C001 AC/DC 9772516 F001 FUSE 0,8A DELAYED 5 X 20 9772551 FUSE BOX + NUT...
- Page 22 13.08.2002/V162001 1029860 MASTERTIG AC/DC 2000 Order no. Part Description 4295710 A002 CONTROL CARD A002 MASTERTIG AC/DC 4277540 A003 CONTROL CARD MAS.TIG AC/DC A003 4280540 A004 CONTROL CARD MAS.TIG AC/DC A004 4283150 C001 CAPACITOR C001 AC/DC 9772516 F001 FUSE 0,8A DELAYED 5 X 20 9772551 F001...
- Page 26 27.11.2001/V162501 2068280 C/1916150 MASTERTIG AC/DC 2500 Order no. Part Description 4295710 A002 CONTROL CARD A002 MASTERTIG AC/DC 4277540 A003 CONTROL CARD MAS.TIG AC/DC A003 4280540 A004 CONTROL CARD MAS.TIG AC/DC A004 4283150 C001 CAPACITOR C001 AC/DC 9755264 C003 CAPACITOR 75 UF 9414086 BOX NUT 9772516...
- Page 31 27.11.2001/V162506 2068340 D/1916160 MASTERTIG 2500W ACDC Order no. Part Description 4295710 A002 CONTROL CARD A002 MASTERTIG AC/DC 4277540 A003 CONTROL CARD MAS.TIG AC/DC A003 4280540 A004 CONTROL CARD MAS.TIG AC/DC A004 4279500 A005 CONTROL CARD A002 KWELD 4000W 4283150 C001 CAPACITOR C001 AC/DC 9414086...
- Page 32 27.11.2001/V162506 2068340 D/1916160 MASTERTIG 2500W ACDC Order no. Part Description 2067130 PROTECTIVE COVER MTIG 1600/2500 AC/DC 3139460 PLASTIC PIECE 4296190 STICKER MASTERTIG AC/DC 4282950 STICKER GAS/WATER ACDC 4282960 VOLTAGE STICKER ACDC 2067060 SIDE PLATE LEFT MTIG2500 ACDC 2067070 SIDE PLATE RIGHT MTIG2500 ACDC 2067080 COVER...
- Page 37 27.11.2001/V163505 2069530 B/1916180 MASTERTIG ACDC 3500W Order no. Part Description 4295710 A002 CONTROL CARD A002 MASTERTIG AC/DC 4277540 A003 CONTROL CARD MAS.TIG AC/DC A003 4280540 A004 CONTROL CARD MAS.TIG AC/DC A004 4279500 A005 CONTROL CARD A002 KWELD 4000W 4283150 C001 CAPACITOR C001 AC/DC 9755268...
- Page 38 27.11.2001/V163505 2069530 B/1916180 MASTERTIG ACDC 3500W Order no. Part Description 9433068 SLOT-HEADED SCREW M6X25 3134270 HOSE CONNECTOR R1/8-M12 9568911 HOSE CONNECTOR R1/8-5ML 9377200 HOSE CLAMP 9370182 PLASTIC HOSE 5/8 BLUE 0,25 2067100 FOOT 2067120 HANDLE MTIG 1600/2500 AC/DC 4280930 HANDLE MTIG 2500 ACDC 2067130 PROTECTIVE COVER...