Kemppi mastertig acdc 1600 Service Manual page 6

TECHNICAL SERVICE MANUAL FOR MASTERTIG ACDC
TROUBLESHOOTING CHART
PROBLEM
Porosity in the weld joint.
No HF ignition
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.
If security code is in use and panel is
locked.
Maximum positive or negative
current adjustment is incorrect.
CAUSE
Shield gas flow is not correct,
leakage in the gas hose or faulty
solenoid valve.
Faulty control card A004.
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.
Wrong security code.
Wrong/changed adjustment in
control card A002.
REMEDY
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.
See also PICTURE 4.
The locked panel can be unlocked at
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.