Service manual
Ver. 1.0
1400
1500
2200
2800
3500
1500
2200
2800
3500
Contents
General
Technical data, switches and connectors
Mastertig function panels
Operating principle
IGBT gate pulse (2800/3500)
Voltage over the lower IGBT (2800/3500)
Voltage after the secondary diodes (2800/3500)
IGBTgate pulse (1400-2200)
Voltage over the lower IGBT (1400-2200)
Voltage after the secondary diodes (1400-2200)
Troubleshooting
Power source control card A001 block diagram
Mastertig-power source´s TIG-section´s functions
Signals between control cards A001 and A002
Signals between control cards A002 and A004
Control card A001 layout (1400/1500)
Control card A001 layout (2000/2200)
Control card A001 layout (2800/3500)
MSD 1-meter unit layout
Control card A002 layout (1500/2200)
Control card A002 layout (2800/3500)
Control card A004 layout (2800/3500)
Control card A001 operation check
Control card A002 operation check
Control card A004 operation check
Notes
3
3-6
7-10
11
12
13
14
15
16
24
25
25
26
26
27
27
28-29
30
31
22
23
23
24
17
18-20
21
2
General
Master- and Mastertig-power sources are MMA and TIG power sources designed for demanding professional use.
Master- and Mastertig-power sources are IGBT-inverters, controlled by PWM-principle.
Operation frequency is approx. 18 kHz.
5 power source sizes are available; 1~ 140 A, 1~ 150 A, 3~ 220 A, 3~ 280 A and 3~ 350 A
Technical data, switches and connectors
Master 1400
1
2
3
1 Main switch S001 and welding current connectors
2 Overheat protection signal lamp
3 Current adj. potentiometer
Supply voltage 1
∼,50/60 Hz
Connection power 20% ED
60% ED
100% ED
Supply cable/ fuses
Welding current range MMA
220V –10%….240V +6%
140 A/ 6,2 kVA
105 A/ 4,4 kVA
75 A/ 2,9 kVA
3 x 1,5S / 16 A slow
15 A / 20,0 V..140 A / 25,6 V
Suitable electrode sizes
Welding power adj.
OCV
∅ 1,5…..3,25 mm
stepless
Approx. 80 V
80% (140 A / 25,6V) Efficiency
Idling power
Degree of protection / Casing class
Weight
Approx. 10 W
IP 23
10 kg
3
Master 1500
1
2
3
4
5
1 Main switch S001, welding current connectors and dynamics adjustment
2 Overheat protection signal lamp
3 Remote controller connection
4 Local / remote control
Supply voltage 1
∼,50/60 Hz
Connection power 20% ED
60% ED
100% ED
Supply cable/ fuses
Welding current range MMA
(TIG
Suitable electrode sizes
Welding power adjustment
OCV
Efficiency
220V –10%….240V +6%
150 A / 6,6 kVA
105 A / 4,4 kVA
75 A / 3,0 kVA
3 x 1,5S / 16 A slow
15 A / 20,5 V..150 A / 26,0 V
5 A / 10,2 V..150 A / 16,0 V)
∅ 1,5…..3,25 mm
stepless
Approx. 80 V
80% (150 A / 26,0 V)
Idling power
Degree of protection / Casing class
Weight
Auxiliary devices
Approx. 10 W
IP 23C
10,5 kg (TIG, 13,5 kg)
Remote controllers
C 100C, C 100D
4
Master 2200
1
2
3
4
5
6
1 Main switch S001, welding current connections and dynamics adjustment
3 Remote controller connecyor
4 Overheat protection signal lamp
5 Remote / local control selection
Supply voltage 3
∼,50/60 Hz
Connection power 25% ED
60% ED
100% ED
Supply cable / fuses
Welding current range MMA
(TIG
Suitable electrode sizes
Welding power adjustment
OCV
Efficiency
380V –10%….415V +6%
220 A / 8,4 kVA
145 A / 5,5 kVA
110 A / 3,5 kVA
4 x 1,5S / 10 A slow
15 A / 20,5 V…220 A / 28,8 V
5 A / 10,2 V…220 A / 18,8)
∅ 1,5…4,0 (5,0) mm
stepless
Approx. 80 V
82% (220 A / 28,8V)
Idling power
Degree of protection / Casing class
Weight
Auxiliary devices
Approx. 10 W
IP 23C
12,5 kg (TIG, 16 kg)
Remote controllers
C 100C, C 100D
5
Master 2800 and 3500
1
2 3 4 5
6
7
1 Main switch S001 and welding current connectors
3 Overheat protection signal lamp
5 Current adjustment potentiometer
6 local / remote control
7 Remote controller connector
Supply voltage 3
∼,50/60 Hz
Connection power 35% ED
60% ED
100% ED
Supply cable/ fuses
Welding current range MMA
(TIG
Suitable electrode sizes
Welding power adjustment
OCV
380V –10%….415V +6%
280 A / 11,5 kVA
213 A / 8,5 kVA
165 A / 6,0 kVA
4 x 1,5S / 10 A slow
15 A / 20,5 V…280 A / 31,2 V
5 A / 10,2 V…280 A / 21,2 V)
∅ 1,5…n. 5,0 mm
stepless
Approx. 75 V
Efficiency
Idling power
Degree of protection / Casing class
Weight
Auxiliary devices
83% (280 A/ 31,2 V) approx. 25 W
IP 23
22 kg (TIG, 27 kg)
Remote controllers
C 100C, C 100D, C100T,
MSD 1
380V –10%….415V +6%
350 A / 15,0 kVA
267 A / 11,0 kVA
207 A / 8,0 kVA
4 x 2,5S / 16 A slow
15 A / 20,5 V…350 A / 34,0 V
5 A / 10,2 V…350 A / 24,0 V)
∅ 1,5…n. 6,0 mm
stepless approx. 75 V
83% (350 A/ 34,0 V) approx. 25 W
IP 23
25 kg (TIG, 30 kg)
Remote controllers
C 100C, C 100D, C100T,
MSD 1
6
Mastertig 1500 and 2200
2
3
1
4 5
1 Main switch S001, dynamics adjustment and welding current connections
2 Current adjustment potentiometer
3 Overheat protection signal lamp
4 Local / remote control selection
5 Remote controller connector
Pulse panel
Pregas time
Pause current Postgas time
2T/4T-selection
Ignition method and process selection
Continous / pulse welding selection, pulse ratio adjustment
Pulse frequency Downslope time
7
Minilog-panel
Pause current Pulse frequency Post gas time
2T/4T-selection
Ignition method and process selection
Downslope time
Minilog-operation selection, minilog-current adjustment
Minilog-functions not in use
Current upslope time, continous welding
Continous welding selection
Pulse welding selection and pulse ratio adjustment
8
Mastertig 2800 and 3500
2
1
3 4 5
6
1 Main switch S001 and welding current connectors
3 Overheat protection signal lamp
5 Current adjustment potentiometer
6 Local / remote control selection
7 Remote controller connector
7
Pulse panel
Pregas time
Pause current
Postgas time
2T/4T-selection
Ignition method and process selection
Continous / pulse welding selection, pulse ratio adjustment
Pulse frequency Downslope
9
Minilog-panel
Pause current Pulse frequency Postgas time
2T/4T-selection
Ignition method and process selection
Downslope
Minilog-function selection, minilog current adjustment
Minilog-functions not in use
Current upslope time adj.
continous welding
Continous welding selection
Pulse welding selection and pulse ratio adjustment
10
Operation principle
The power stage in Master- and Mastertig- power sources is a traditional half-bridge, where the intermediate circuit´s dc-voltage is halved by load capacitors C2 and C3. IGBT-transistors are used as power switches. When both IGBTs are not conductive, no power is transferred. When the upper IGBT (V2) is conductive, there is positive voltage in the main transformer´s (T1) primary, and when the lower IGBT (V3) is conductive there is negative voltage in the main transformer´s
(T1) primary.
Power is adjusted by altering the IGBT timings (PWM). The main transformer (T1) secondary voltages are rectified by a full-wave rectifier.
U
G2 approx. + 320 V (1~) or approx. + 570 V (3~)
V2 t
U
G3
C2
U
1
U
G2
T1 t
U
1
V3
C3
U
G3 t
U
2
U
2 t
Voltage over the lower IGBT V3 with minimum power (3~) Voltage over the lower IGBT V3 with maximum power (3~)
11
IGBT gate pulse (Master / Mastertig 2800/3500)
A
A
IGBT gate pulse with minimum power (2800/3500). Inverter operating frequency approx. 19 kHz (measuring point A).
A
IGBT gate pulse with maximum power (2800/3500). Inverter operating frequency approx. 19 kHz (measuring point A).
12
Voltage over the lower IGBT (Master / Mastertig 2800/3500)
B
B
Voltage over the lower IGBT with minimum power (2800/3500). Inverter operating frequency approx. 19 kHz (measuring point B).
B
Voltage over the lower IGBT with maximum power (2800/3500). Inverter operating frequency approx. 19 kHz (measuring point B).
13
Voltage after the secondary diodes (Master / Mastertig 2800/3500)
C
C
Voltage over the secondary diodes with minimum power(2800/3500). Frequency is approx. 38 kHz (measuring point C).
C
Voltage over the secondary diodes with maximum power (2800/3500). Frequency approx. 38 kHz (measuring point C).
14
IGBT gate pulse (Master / Mastertig 1400/1500/2200)
D
D
IGBT gate pulse with minimum power (1400/1500/2200). Inverter operating frequency approx. 18 kHz (measuring point D).
D
IGBT gate pulse with maximum power (1400/1500/2200). NOTE. Inverter operating frequency approx. 25 kHz (measuring point D).
15
Voltage over the lower IGBT (Master / Mastertig 1400/1500/2200)
E
D
Master 1400/1500
E
D
Master 2200
E
D
Lower IGBT control (Gate pulse; measuring point D / Voltage over the lower IGBT; measuring point E).
16
Voltage after the secondary diodes (Master / Mastertig 1400/1500/2200)
F F
F
D
Master 1400/1500
D
Master 2200
D
Voltage after the secondary diodes (measuring point F) and lower IGBT gate pulse (measuring point D).
17
Troubleshooting
The machine may be repaired only by an authorized and licensed technician or workshop!
First do a visual check to find the possible loose connectors, broken wires or signs of overheating.
Also check the condition of the welding cables, welding guns / torches and all consumable parts.
Troubleshooting diagram
DISTURBANCE
The power source will not start.
MMA open circuit voltage is 0 V
The net fuses blow during startup.
POSSIBLE CAUSE
Net fuses have blown
Faulty supply cable
Faulty main switch
REMEDY
Check the net fuses
Check the supply cable condition
Check the main switch condition
Check the potentiometer condition Faulty current adjustment potentiometer
Faulty local / remote control selection switch (2200-3500)
Faulty auxiliary transformer
Faulty primary side power semiconductor
Faulty control card A001
Faulty control card A002
(Mastertig)
Faulty flat cable between control cards A001 and A002
Faulty primary side power semiconductor
Faulty main circuit card
Check the control method selection switch condition
Check the auxiliary transformer condition
Check the condition of the primary rectifier and the IGBT-module
Check the control card A001 condition (see page 27)
Check the control card A002 condition (see pages 28 and 29)
Check the flat cable condition
(see page 23)
Check the condition of the primary rectifier and IGBT-module
Check the condition of the smoothing and load capacitors.
Look for possible signs of insulation damages on main circuit card.
Faulty secondary unit Check the secondary diodes condition.
Note! 1-phase Master- and Mastertig-power sources may blow net fuses during the first startup, without being anything wrong in the power source. This is because the DC-link capacitors have relatively high charging current! This phenomenon is found especially with automatic fuses.
18
DISTURBANCE
The power source will not deliver full power
POSSIBLE CAUSE
A net fuse has blown
Faulty supply cable
REMEDY
Check the net fuses
Check the supply cable condition
Faulty main switch
Faulty primary side power semiconductor
Faulty control card A001
Check the main switch condition
Check the primary rectifier and
IGBT-module
Check the correct pulse ratio adjustment from control card A001 to IGBT gate (see pages 12 and 15)
The power source will not operate on TIG
Faulty main circuit card
Faulty secondary unit
Faulty main transformer
Check the main circuit card capacitors and their connections
Check the condition the secondary diodes
Check the main transformer ferrites
Faulty control card A002
(Mastertig)
Check the flat cable signals between control cards A001 and
A002; pins 1 and 2 against the card´s GND (see pages 28 and 29)
Faulty flat cable between control cards A001 and A002
Check the flat cable´s condition
(see page 23)
Check power source´s operation on MMA. Disconnect the flat cable from control card A001 and connect a shortcircuit loop to the flat cable connector X3, between pins 1 and 2. If the power source doesn´t work on MMA , then the TIG process can not work either.
Faulty flat cable between control cards A001 and A002
Check the flat cable condition
(see page 23)
Faulty control card A002 Check control card condition
(see pages 28 and 29)
TIG-spark ignition doesn´t work.
Scratch ignition method is OK.
On MMA the machine works
OK.
Faulty flat cable between control cards A001 and A002
Faulty control card A002
Faulty control card A004
(2800/3500)
Check the flat cable condition
(see page 23)
Check the control card A002 condition
(see pages 28 and 29)
Check the control card A004 condition (see page 30)
19
DISTURBANCE
TIG-process logic functions are not working correctly
POSSIBLE CAUSE
Faulty adjustment potentiometer
Faulty flat cable between control cards A002 and A003
REMEDY
Check the adjustment potentiometers
Check the flat cable
(see page 23)
Mastertig 3500 W-cooling unit doesn´t stay on, when operated by it´s start switch
Mastertig 3500 W-cooling unit doesn´t start, when operated by it´s start switch
Faulty control card A002
Faulty pressure switch
Faulty control card A005
The fuse F002 has blown
Faulty switch
Faulty auxiliary transformer
T004
Pump is jammed
Faulty startup capacitor
Faulty pump motor
Replace control card A002
(see pages 28 and 29)
Check the pressure switch
Check the control card A005 relays
Check the fuse and the fuse holder
Check the switch
Check the auxiliary transformer
T004
Check and clean the pump
Check the startup capacitor.
Check the pump motor
20
Control card A001 block diagram
Current instruction
Set value circuit
MMA ignition
Controller and
PWM development
Gate buffers
Control to IGBT
TIG/MMA
Locking
U2
MMA dynamics
OCV adjustment
I2
AV~40
Actual current value
Fan control
Overheat protection
Power supply
Net voltage watch
Current information to TIG
The functions of power source´s control card A001 are built around the PWM-controller SG
3526.
Gate buffer
PWM-controller develops PWM-signals, that are amplified in the gate buffer and taken via a control transformer to the IGBT-module´s gates.
Set value circuit
Set value circuit prepares the signal coming from the potentiometer suitable for the PWM-controller and protects the electronics from potentiometer circuit´s insulation faults and possible overvoltages.
MMA ignition
The MMA ignition circuit develops an overcurrent spike to the set value current in order to ease the ignition.
MMA Dynamics
The dynamics circuit develops overcurrent spikes to the set value current during short circuits.
Locking
The locking circuit prevents the MMA ignition current and dynamics operation on TIG.
OCV controller
The OCV circuit controls the power stage during idling so that the power losses are minimized.
Shunt amplifier
Current signal amplifier amplifies the shunt voltage suitable for the PWM-controller.
Fan control
PWM-signal is used to control the fans on/off. During idling the PWMcontroller´s pulse ratio is so low , that the fans are off. The fans start after 30 seconds from the start of welding, regardless of the welding current level. Postwelding cooling is active for 5 minutes.
Overheat protection
Overheat protection is activated by PTC-resistors.
Power supply
The power supply section forms the auxiliary voltages needed by control card A001. The power supply section also provides undervoltage watch.
Net voltage watch
Net voltage watch circuit stops the power stage, in case the net voltage rises above certain limit.
21
Mastertig-power source´s TIG-section
The TIG-section provides these programmatic functions:
•
Pre- and postgas timings
•
Up- and downslopes
•
Tacking automatics
•
Switch functions (2T/4T)
•
Pulse functions
•
Pulse led control
•
Ignition spark control and watch
•
Contact ignition control and watch
•
Power source start and set value
24 VAC
+ 16 V
Operation voltage section
+ 5 V
24 VAC
Spark generator
Spark on/off
Controller part
+ 16 V
Resetgenerator
Reset
Solenoid valve
LED
Start
Start
-indication
10 kV
22
Signals between control cards A001 and A002 (Mastertig 1500-3500)
3
4
1
2
Current set value from power source (0,5…5 Vdc)
Current set value to power source (0,5…5 Vdc)
GND
GND
7
8
5
6
GND
GND
Output voltage information from power source
(OCV on MMA is approx. 75 Vdc)
9
10
11
12
13 MMA/TIG-selection (TIG = 4,5 Vdc, MMA = 0 V)
14 26 Vac from power source
15 26 Vac from power source
16 16 Vac from power source
Signals between control cards A002 and A004 (Mastertig 2800-3500)
5/1
5/2
5/3
X6/3 (A004)
26 Vac
Spark generator on/off
Start switch detection
GND
23
Control card A001 layout (Master / Mastertig 1500)
X11 X10
X8 X4
X17
X16
X2
R70
X15
R48
R47
X18
X3
R98
X1
R49
R47 Maximum current
R48 MMA ignition current
R49 Minimum current
R70 Inverter frequency
R98 Set value min. (TIG)
X15
X15
X16
X17
X18
X18
Control card A001 layout (Master / Mastertig 2000/2200)
MMA
Scratch-TIG
OCV approx. + 80 V
OCV approx.. + 40 V
X20
X11 X10
X16
X17
X8 X5 X4
R70
X2
X15
R48
X18
R47
R98
X1
R49
X3
X14
X13
X12
R47 Maximum current
R48 MMA ignition current
R49 Minimum current
R70 Inverter frequency
R98 Set value min. (TIG)
X17
X17
X18
X18
X15
X15
X16
X16
MMA
Scratch-TIG
Net voltage 3
∼ 400 V
Net voltage 3
∼ 460 V
Net voltage 3
∼ 460 V
Net voltage 3
∼ 400 V
OCV approx. + 80 V
OCV approx. + 40 V
24
Control card A001 layout (Master / Mastertig 2800/3500)
X20
X11
X11
X10
X10
X8
X8
X5
X5
X4
X4
X14
X15
X16
X2
X17
X2
X12
X15
R53
X16
R48
R33
X18
R93
R47
X17
X3
X3
X18
R49
X1
X1
R33 Maximum current
R53 MMA ignition current
R72 Minimum current
R75 Inverter frequency
R93 Set value min. (TIG)
X16
X16
X17
X17
X18
X18
X15
X15
MSD 1-meter unit layout (Master / Mastertig 2800/3500)
MMA
Scratch-TIG
Net voltage 3
∼ 400 V
Net voltage 3
∼ 460 V
Net voltage 3
∼ 460 V
Net voltage 3
∼ 400 V
OCV approx. + 80 V
OCV approx. + 40 V
X4
R4
R3 R5 R6
X3
R3 Set value current minimum
R4 Set value current maximum
R5 Voltage
R6 Current
X3 Short circuit loop must be disconnected in
Mastertig 2800 / 3500-power sources
X4 Machine size coding
(Master and Mastertig 2800 / 3500)
25
Control card A002 layout (Master / Mastertig 1500/2200)
X11
JUMPERS
When a jumper is disconnected:
X12 Tacking automatics goes off
X13 Downslope time becomes non-linear, downslope times become longer with low currents
X14 Postgas becomes independent from set value, and adjustable linearly adjustable between 0 - 120s
X15 Downslope will go all the way to the minimum, and won´t be cut-off at 15 % level of the welding current
X16 Contact ignition current changes 40A -> 25A
X17 Minilog-functions enabled
X18 Empty
X19 Current rise-up speed maximum
X22 ALWAYS KEEP CONNECTED!!
R43 Spark voltage adjustment
Control card A002 layout (Master / Mastertig 2800/3500)
X1
X5
X3
X4
JUMPERS
When a jumper is disconnected :
X12 Tacking automatics is off
X13 Downslope time is non-linear, downslope times become longer with low currents
X14 Postgas becomes independent from set value, and adjustable linearly adjustable between 0 - 120s
X12…….X19
X21 X20
F1 0,63 AT
X15 Downslope will go all the way to the minimum, and won´t be cutoff at 15 % level of the welding current
X16 Contact ignition current changes 40A -> 25A
X17 Minilog-functions enabled
X18 Empty
X19 Current rise-up speed maximum
26
Control card A004 layout (Master / Mastertig 2800/3500)
X6
F1 1,6AT
R13
R1
X5
X4
Control card A001 functional testing
Control card power supply ?
(2 x 13 Vac)
Temperature watch PTC ?
Set value information ?
5AT 3.1
5AT 3.1
IGBT gate pulses
Control card A001 develops the IGBT gate pulses. If the power supply part is OK, the fuses are intact, the temperature watch PTCs are OK and correct set value info is received from the potentiometer, then the gate pulses should be seen on connectors X10 and X11.
When the machine is idling, one must note that it is actually running intermittently.
27
Control card A002 functional testing
7
8
5
6
3
4
1
2
Current set value to power source (0,5…5 Vdc)
Current set value to power source (0,5…5 Vdc)
GND
GND
GND
GND
Output voltage from power source
(OCV on MMA 75 Vdc)
9
10
11
12
13 MMA/TIG-selection (TIG = 4,5 Vdc, MMA = 0 V)
14 26 Vac from power source
15 26 Vac from power source
16 16 Vdc from power source
The control card A002 uses the 24 Vac to control the solenoid valve and spark ignition, and transforms the + 16 V voltage to + 5 V for control electronics.
Control card A002 alters the signal taken from control card A001´s (pin 1) set value circuit according to the adjustments of the operating panel (pin2). It also controls the spark ignition and solenoid valve.
The power source is controlled by the signal from flat cable´s pin 2 and changes in the operating panel´s adjustments affect signal in pin 2. On TIG the pin 2 has voltage only when the start is active and the machine is loaded.
Examples of the voltages on flatcable´s pins 1 and 2:
A=Pin 2 voltage
Pulse ratio approx. 50 %, pause current 40 % and cycle time 1,5 s (0,7 Hz)
B=Pin 1 voltage
Set value information from control card A001´s set value circuit
28
A=Pin 2 voltage
Pulse ratio approx. 10 %, pause current 40 % and cycle time 1,5 s (0,7 Hz)
B= Pin 1 voltage
Set value information from control card A001´s set value circuit
A= Pin 2 voltage
Pulse ratio approx. 50 %, pause current 40 % and cycle time approx. 0,2 s (50Hz)
B= Pin 1 voltage
Set value information from control card A001´s set value circuit
A= Pin 2 voltage
Pulse ratio approx. 50 %, pause current min. and cycle time approx. 0,2 s (50Hz)
B= Pin 1 voltage
Set value information from control card A001´s set value circuit
29
Control card A004 functional testing (Mastertig 2800/3500)
5/1
5/2
5/3
X6/3 (A004)
24 Vac
Spark generator on/off
Start switch detection
GND
Mastertig 2800/3500 control card A004 generates the ignition spark for TIG and it also reads the torchswitch states. The torch switch is separated from other electronics on the transformer, because the voltage inducted to the switch lines is almost full spark voltage
(approx. 10 kV).
The torch switch state is measured by the connector X5/3, according to these voltage limits:
Measured between X5/3 and ground
Torch switch open Torch switch closed
After closing the torch switch the power stage will start and the output voltage will rise.
Power for the ignition spark is taken from the power source´s output voltage, from which a spark of approx. 10 kV is developed. The spark generator is started via connector X5/2.
Measured between connectors X5/1 and X5/2
Ignition spark off Ignition spark on
30
Notes
31
