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Table of Contents
Related Manuals for Kemppi Mastercool 30
Summary of Contents for Kemppi Mastercool 30
- Page 1 SERVICE MANUAL Mastercool 30 Kemppi Oy...
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Page 2: Table Of Contents
4.3.2.2. Over pressure alarm ......................... 13 4.3.2.3. Normal operational pressure ....................13 4.3.2.4. Water flow test .......................... 13 4.3.3. Cooler voltages ..........................14 5. FIRST GENERATION CONTROL CARD SP002447 ..................15 6. SECOND GENERATION CONTROL CARD SP004736 ................16 APPENDIX ................................17 Kemppi Oy... -
Page 3: Read This First
Service manual Mastercool 30 Version 1.0 1.11.2011 1. READ THIS FIRST Before removing any covers or commencing any testing or measurement disconnect the power source from the mains voltage DC voltage may still exist after the removal of the input voltage. Machine discharges the voltage while it is turned off, but it is always better to ensure this by measuring the voltage Wait at least one minute for the capacitors to become discharged. -
Page 4: General
1.11.2011 2. GENERAL Mastercool 30 is membrane pump type cooler for water cooled mig guns. Membrane pump can generate up to 10 bar pressure so it needs electronically limited control logic. Control logic and pump motor both uses low voltage power (+24VDC) and cooler does not have any high voltage inside. -
Page 5: Technical Information
Service manual Mastercool 30 Version 1.0 1.11.2011 3. TECHNICAL INFORMATION 3.1. Technical data Mastercool 30 Operating voltage 24VDC Cooling power 1.0 kW Connection capacity 100% ED Maximum pressure 4.0 bar 12.9 A 100 % ED I Cooling liquid 20% - 40% glycol-water Tank volume Approx. -
Page 6: Construction
Service manual Mastercool 30 Version 1.0 1.11.2011 3.3. Construction Left side Front Back Right side The cooling fan is installed so that the air flows from the left side plate to Z001 card. Air comes out through the front and the back plate grills. -
Page 7: Inner Structure
Service manual Mastercool 30 Version 1.0 1.11.2011 3.3.1. Inner structure 1. Fastening points to power source 2. Hot water/return snap connector (red) 3. Cool water/output snap connector (blue) 4. Hydrocool pump 5. A001 control card 6. Water tank filling hose 7. -
Page 8: A001 Control Card Structure
Service manual Mastercool 30 Version 1.0 1.11.2011 3.3.2. A001 control card structure Connector X5, not in use Connector X7, Positive output for pump motor Connector X8, Negative output for pump motor Connector X4, PTC and cooling fan connector Connector X3, Control connector to power source... -
Page 9: Description Of Operation
Version 1.0 1.11.2011 3.4. Description of operation Mastercool 30 can be divided to three parts: A001 control card, pump with motor and water circulation components. Note that Mastercool has had two different principles for pressure dampening and three different types of control cards depending the manufacturing time. -
Page 10: Control Card Jumpers
Service manual Mastercool 30 Version 1.0 1.11.2011 Generation 2 pressure damper system has a normal rubber single output water hose and it is connected to disk-like pressure damper. It is made of copper and has a single chamber to reduce the pressure variations. This type damping circuit is used since 4/2010. -
Page 11: Service Instructions
4. SERVICE INSTRUCTIONS 4.1. Cooling liquid With Mastercool 30 it is possible to use two kind of cooling liquids: Water mixed with ethanol or glycol. Ethanol based coolant is recommended for better torch durability. It also keeps the pump clean and smoothly running. -
Page 12: Fastening The Generation1 Dual Water Hose To The Pump
Service manual Mastercool 30 Version 1.0 1.11.2011 Water hose nib Rubber sealing ring for the copper pipe 4.2.2. Fastening the Generation1 dual water hose to the pump It is important to make connection right way because otherwise connection may leak or even hose slip away. -
Page 13: Measurements And Tests
Service manual Mastercool 30 Version 1.0 1.11.2011 Open the pump crown and check the pressure valves if they are clean and intact • Clean the area around the valves and replace valves if needed • Note! Be careful while installing valves, they must be in right sides, if not pressure won’t •... -
Page 14: Operational Tests
Service manual Mastercool 30 Version 1.0 1.11.2011 If problems continue close X10 to disable over pressure alarm • If these do not help, the problem is not the over pressure, see the next section (Under pressure or no water circulation). -
Page 15: Over Pressure Alarm
Service manual Mastercool 30 Version 1.0 1.11.2011 4.3.2.2. Over pressure alarm When water circulation is blocked or resistance is too high, control electronics activate alarm If pressure is over approx. 5 bars led H2 illuminates • This can be simulated by bending output water hose just after the snap connector •... -
Page 16: Cooler Voltages
Service manual Mastercool 30 Version 1.0 1.11.2011 4.3.3. Cooler voltages Voltage measuring gives basic information of possible problems. Mastercool 30 requires +24 VDC for control electronics, pump motor and cooling fan. Input voltage from the power source: +24VDC X3-3 •... -
Page 17: First Generation Control Card Sp002447
Service manual Mastercool 30 Version 1.0 1.11.2011 5. FIRST GENERATION CONTROL CARD SP002447 X7/X8 Change machine pressure-/flow characteristic curve. Open - the pressure is lower closed – higher pressure Cooling unit start *Open – waiting for start signal Closed – Continuous run Liquid temperature alarm. -
Page 18: Second Generation Control Card Sp004736
Service manual Mastercool 30 Version 1.0 1.11.2011 6. SECOND GENERATION CONTROL CARD SP004736 X22 and X20 Cooling unit start. *Open – Waiting for power source start signal Closed – Continuous run Liquid temperature alarm. *Open – PTC monitoring by cooler Closed –... -
Page 19: Appendix
Service manual Mastercool 30 Version 1.0 1.11.2011 Notes Kemppi Oy...
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