Troubleshooting Chart - Kemppi mastertig acdc 1600 Service Manual

TECHNICAL SERVICE MANUAL FOR MASTERTIG ACDC

TROUBLESHOOTING CHART

PROBLEM
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
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.
CAUSE
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.
Overvoltage in mains supply line.
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.
REMEDY
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 OR IT IS NOT WORKING
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.
Check the mains supply line. The
approx. voltage limits are mentioned
in TABLE 4.
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 1., is faulty.
Check and change the pcb or IGBT.