tig kemppi ac dc servis.pdf

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Service manual
Ver. 1.0
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Contents
Technical data …………………………………………… 4, 5
Switches and connectors …....……………………………6-8
Function panels …......…………………………………… 8, 9
Jumper functions …...................................…...…………..10, 11
Error codes ………………………………………………. 12
Operation principle ………………………………………12-14
Block diagram …………………………………………….14
Filter cards ……………………………………..…………15, 16
Filter card layout ………………………...........………… 16, 17
Main circuit cards ………………………………………..18, 19
Main circuit cards layout ………………………………...19, 20
Voltage selector switch (2500) ………………………… 21
Secondary circuit components …………………………..21, 22
Diode card layout ……………………………………...…23
Cooling unit …………………………………………….... 23
Filter card Z004 layout ………………………………......24
Cooling unit control card A005 ………………….........…24
Control card A005 layout ……………………………….. 25
Control card A001 functions ………………………….....25
Control card A001 connectors ………………………….. 26
Control card A002 functions and connectors …..………27, 28
Control card A002 layout ………………………………. 29
Control card A003 functions and connectors ………….. 30
Control card A003 layout ………………………………. 31
Control card A004 functions and connectors ………….. 32
Control card A004 layout …………………………….…. 32
Structure ……………………………………………..….. 33-35
Troubleshooting ………………………………………..... 36, 37
Net voltage functional limits …..............................………38
Signals between control cards A001 and A002 …………38-46
Measurings from control card A002 connector X8 ….…46, 47
Measurings from control card A002 connector X9 ….....48, 49
Measurings from control card A002 connector X10 …...50-52
Measurings from control card A002 connector X11 …...52, 53
Measurings from control card A002 connector X20 …...53
Measurings from control card A003 connector X3 …….54, 55
Measurings from control card A003 connector X8 ….....56, 57
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Contents
Mastertig 2000 AC/DC inverter controls ……….............57-65
Sec. voltage U 2 using low-pass filter (2000) …..................65-69
Mastertig 2500 AC/DC inverter controls ……….............70-73
Sec. voltage U 2 using low-pass filter (2500) …................. 73-76
Mastertig 3500 AC/DC inverter controls ……............….77-79
Sec. voltage U 2 using low-pass filter (3500) …................. 80-83
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Technical data
Mastertig AC/DC
2000
Supply voltage
1 - 50 / 60 Hz
230 V +-10 %
Connection power
TIG
max.
200 A / 6,8 kVA
100 %
150 A / 4,5 kVA
MMA
max.
160 A / 7,3 kVA
100 %
100 A / 4,2 kVA
Welding current range
TIG
DC
3 A / 10 V … 200 A / 18 V
AC
10 A / 10 V … 200 A / 18 V
MMA
DC
10 A / 10 V … 160 A / 26,4 V
AC
11 A / 10 V … 160 A / 26,4 V
Connection cable
3 x 2,5 mm2 S- 3
Fuse
16 A Slow
Loadability**
TIG AC
30 %
ED ( T = 40 C)
200 A / 18 V
100 %
ED ( T = 40 C)
150 A / 16 V
MMA
20 %
ED ( T = 40 C)
160 A / 26,4 V
100 %
ED ( T = 40 C)
100 A / 23,6
Fuse
20 A Slow
Loadability***
TIG AC
50 %
ED ( T = 40 C)
200 A / 18 V
100 %
ED ( T = 40 C)
150 A / 16 V
MMA
60 %
ED ( T = 40 C)
160 A / 26,4 V
100 %
ED ( T = 40 C)
140 A / 23,6
OCV
DC and AC
70 V DC
AC Frequency
Fixed/adjustable
60 Hz / 50 … 200 Hz
Efficiency
75 % ( 160 A / 26,4 V )
Power factor
0,8 ( 160 A / 26,4 V )
Idling power
18 W
Temp class/degree of prote c tion
B ( 130 C ) H ( 180 C )/ IP 23 C
*) Adjustable in minilog and pulse panels
**) fuse size limits the loadability
*** ) 20 A fuse requires the change of the supply cable
4
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Technical data
Mastertig AC/DC
2500 and 2500 W
3500 W
Supply voltage
3~50/60 Hz
230,400,460V +/-10%
400 V + / - 10%
Loadability
TIG 70% ED
250 A / 7,5 kVA
350 A / 11,7 kVA
TIG 100% ED
200 A / 6,7 kVA
320 A / 9,3 kVA
MMA 40% ED
250 A / 10,3 kVA
MMA 60% ED
350 A / 15,7 kVA
MMA 100% ED
200 A / 7,9 kVA
280 A / 11,2 kVA
Fuse
230 V
20 A Slow
400 V
16 A Slow
20 A Slow
460 V
16 A Slow
W elding current range
TIG DC
3 A / 10 V … 250 A / 20 V
3 A / 10 V … 350 A / 24 V
TIG AC
10 A / 10 V … 250 A / 20 V
10 A / 10 V … 350 A / 24 V
MMA DC
10 A / 20 V … 250 A / 30 V
10 A / 20V … 350 A / 34 V
MMA AC
10 A / 20 V … 220 A / 30 V
10 A / 20V … 350 A / 34 V
OCV
70 V DC
70 V DC
AC frequency
Fixed/adjustable
60 Hz / 50 … 200 Hz
60 Hz / 50 … 200 Hz
Efficiency
80 % ( 250 A / 30 V )
80 % ( 350 A / 34 V )
Power factor
0,9 ( 250 A / 30 V )
0,9 ( 350 A / 34 V )
Temp class
B ( 130 C ) H ( 180 C )
B ( 130 C ) H ( 180 C )
Degree of protection
IP 23 C
IP 23 C
Dimensions
L, W, H (mm)
690 x 260 x 550, 830
690 x 260 x 870
Weight
Kg
39 / 65
74
Coolant max. press.
350 kPa
350 kPa
Cooling unit power
1300 W
1300 W
5
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