Service manual

Ver. 1.0
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
Contents

Mastertig 2000 AC/DC inverter controls……….............57-65

Sec. voltage U2 using low-pass filter (2000)…..................65-69
Mastertig 2500 AC/DC inverter controls……….............70-73
Sec. voltage U2 using low-pass filter (2500)…................. 73-76
Mastertig 3500 AC/DC inverter controls……............….77-79
Sec. voltage U2 using low-pass filter (3500)…................. 80-83
Technical data
Mastertig AC/DC 2000
S upply 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
W elding 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 S low
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 S low
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 protection 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
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
W eight Kg 39 / 65 74
Coolant max. press. 350 kPa 350 kPa
Cooling unit power 1300 W 1300 W

5
Switches and connectors

Main switch

Shielding gas connection

TIG-torch connection

Control cable connection, TIG-torch

Welding current connection

Return current connection

Control cable connection, remote controller
Supply cable

Mastertig 2000 AC/DC

Main switch
Shielding gas connection

Welding current connection

Control cable connection, TIG-torch

TIG-torch connection

Control cable connection, remote controller

Return current connection

Supply cable

Mastertig 2500 AC/DC

6
Switches and connectors

Main switch
Shielding gas connection

Welding current connection

Control cable connection, remote controller

Supply cable Return current connector

TIG-torch connector

Mastertig 2500W AC/DC

Main switch

Welding current connection

Control cable connection, remote controller

Return current connector

Supply cable
Shielding gas connection

TIG-torch connector

Mastertig 3500W AC/DC

7
Switches and connectors

Pressure too low -signal lamp

Coolant overheating -signal lamp

Test switch

Torch cooling method selection

Function panels

1 TIG HF ignition /current selection

22 TIG contact ignition/current selection
3 Post gas time adjustment 0…100 s.
4 Welding current downslope adj. 0…15 s.
5 Current adj. knob/parameter adjustment
6 Local-/remote control selection/code lock
12 Pregas time adjustment/code lock
13 Welding current upslope adjustment 0…5 s.
14 2T/4T-selection
19 Broken arc
21 MMA welding selection

Basic panel

8
Function panels
1 TIG HF ignition/ contact ignition selection
2 AC-TIG frequency adjustment 50…200 Hz
3 Postgas time adjustment 0…100 s.
4 Welding current downslope time adjustment 0…15 s.
5 Current adjustment knob/selected parameter adj
6 Local-/remote control selection/code lock
11 Minilog-function selection/adjustment -80…+20 %
12 Pre gas time adjustment/code lock
13 Welding current upslope time adjustment 0…5 s.
14 2T/4T-selection
19 Broken arc welding
20 MMA welding dynamics adjustment
21 MMA welding selection
22 AC-TIG balance adjustment -70…+70 %

Minilog-panel

1 TIG HF ignition/ contact ignition selection

2 AC-TIG frequency adjustment 50…200 Hz
3 Postgas time adjustment 0…100 s
4 Welding current downslope time adjustment 0…15 s.

5 Current adjustment knob/selected parameter adj

6 Local-/remote control selection/code lock
7 Pulse-TIG pulse height adjustment 3…200, 250,
350 A/pulse ratio adjustment 10…75 %
8 Pulse-TIG selection
9 Pulse-TIG background current adjustment 20…40 %/
frequency adjustment 0,1…300 Hz
10 Start current adjustment-70...+70 %
11 Minilog-function selection/adjustment -80…+20 %
12 Pregas time adjustment/code lock
13 Welding current upslope time adjustment 0…5 s.
14 Fusion spot welding selection/adjustment 0…10 s.
15 2T/4T-selection
16 Memory channels selection
17 Welding values saving into the memory channels
18 Memory channel selection
Pulsepanel
19 Broken arc welding
20 MMA welding dynamics adjustment
21 MMA welding selection
22 AC-TIG balance adjustment -70…+70 %

9
Jumper functions

The power source has extra functions and selections, that can´t be seen on the display normally.
The jumper functions can sometimes solve special problems. The jumper function can be a simple
on/off type function or it may have an adjustable value.

Jumper functions in use:

1. Shut down the power source by the main switch

2. Press and hold down the post gas button (3) and simultaneously turn the main switch S001 to
ON.
3. Press the pregas button(12) once. J01 is shown on the display.
4. Choose the jumper to be adjusted by REMOTE (6) button.
5. Change the jumper setting by the current adjustment knob (5).
6. To save the settings, finally press the post gas time (3) button.

10
Jumper functions

Jumper ON OFF
J01 Upslope angle is constant, time is dependant Upslope set time remains constant, not
Upslope on the set value. depending on the set value.
J02 Downslope angle is constanttime is Downslope set time remains constant, not
Downslope dependant on the set value. depending on the set value.
J03 TIG antifreeze is on. TIG antifreeze is not on.
TIG antifreeze
J04 Manual AC balance adjustment. Balance automatics is on.
AC balance
J05 Tacking automatics is disabled. Tacking automatics is enabled.
Tacking automatics
J06 The downslope drops to minimum current The downslope drops to the end level,
Downslope cut-off (3A DC, 10A AC). which is 20% of the welding current.
level
J07 OCV is 39V. (22V/VRD) OCV is 70V.
OCV
J08 In the ending of the 4T function the Normal 4T function.
“china logic” downslope is started by pressing the torch
switch. The downslope is on while the
switch is pressed, welding current is cut-off
when the switch is released. If it is pressed
for a longer time than the downslope, then
the current remains on the end current level
(see J06).
J09 Inverter frequency is 18 kHz on the whole Inverter frequency is 18kHz/36kHz on
Inverter frequency current level. MMA.
J10 Hot/soft–start is in use wit TIG 2T-function. Hot/soft–start is not in use with TIG 2T-
2T hot/soft-start function.
J11 Hot/soft–start time with 2T-function.
2T hot/soft–start Adjustment range is 0,0- 9,9 s.
time adjustment
J12 On 2T the downslope is not cut-off by a On 2T the welding is stopped by a short
2T downslope short (nor long) press on the switch. pres on the switch during the downslope.
J13 On AC-TIG the height of the pos. half-cycle On AC-TIG the height of the pos. half-
AC-welding positive is the same as the negative half-cycle´s cycle depends on the set value and balance
half-cycle height. adjustments.
J14 Torch switch short press time limit is 0,3 s. Torch switch short press time limit is 0,7 s.
Start switch short
press
J15 AC-TIG-welding is started with a negative AC-TIG-welding is started with a positive
AC-TIG start cycle half-cycle. half-cycle.
J16 Length adjustment for the DC start of the Factory setting is 1.
AC-TIG start cycle positive half cycle in AC-TIG 0.0 .... 2.0.
length
J17 MMA ignition pulse height adjustment 0.0 Factory setting is 1.
MMA ignition pulse ..... 2.0.
J18 - -
J19 - -

11
Error codes

Err1 Power source secondary voltage is > + 90 V for overi 4 seconds.i

Uin Err Net overvoltage

Operation principle
Mastertig AC/DC-power sources are designed for demanding professional use, suitable for TIG-
/MMA welding, both AC and DC. Mastertig AC/DC-power sources are IGBT-inverter power
sources, based on PWM-principle. Operating frequency is 18/36 kHz.

Mastertig AC/DC comes in three sizes; 1~ 200 A, 3~ 250 A and 3~ 350 A.

Mastertig AC/DC-power sources offer 3 different types of function panels; basic panel, minilog-
panel and pulse panel.

Mastertig AC/DC´s function are controlled by a microcontroller (panel mounted), so all

functions are carried out programmatically.

The operating principle of Mastertig AC/DC-power sources is shown below:

UG2
C2 V2
t
UG2 UG3

t
C3 V3 U1

U1 UG3
t

T001

The primary inverter is a traditional half-bridge, where the intermediate circuit DC is halved by
working capacitors C2 and C3.
When the upper IGBT (V2) is conductive, the primary transformer T001 primary has positive
voltage and when the lower IGBT (V3) is conductive, it is negative. Welding power is altered by
altering the transistor timings (PWM).

12
Operation principle
The main transformer T001 secondary voltages are rectified with a full wave rectifier V4 and
the current type (DC+, DC- or AC) is chosen by IGBTs V5 and V6. Secondary circuit current is
measured by shunt resistor R001.
R001

T003
TIG
T001

V5

UG5
V4

V6

When the current type is DC+, is IGBT V5 conductive.

R001

T003
TIG
T001

V5

V4

V6
UG6

When current type is DC-, is IGBT V6 conductive.

13
Operation principle
R001

T003
TIG
T001

V5

UG5
V4

V6

When the chosen current type is AC, then the IGBTs V5 and V6 are conductive one at a time,
with 50…200 Hz frequency.

Block diagram Spark transformer

Primary Primary Main Sec. Sec.

EMI-filt. rectifying Filtering inverter transformer rectifying inverter

Cooling unit Primary inverter Sec. Inverter

Spark card
control card control card Control card
A004
A005 A002 A003

P001
P
14
Filter cards

To the primary rectifier

GND
+ 15 V
Control

Information of overvoltage to
control cards A002 and A001

Mastertig 2000 AC/DC Z001

L1
L1
L2 To primary rectifier
L3

DC link +
DC link -
L3

+ 15 V
Overvoltage watch
Protection circuits against wrong supply voltage
GND

Mastertig 2500 AC/DC Z002

15
Filter cards

Intermediate circuit DC To the primary rectifier L1, L2, L3

+ 15 V
Watch
GND

Aux. Transformer T002

L1, L2 primary 400 Vac

Information of overvoltage to
control cards A002 and A001

Mastertig 3500 AC/DC Z002

The filter cards Z001 (2000) and Z002 (2500/3500) have overvoltage protection against low
energy voltage spikes coming from the net, an EMI-filter against electromagnetic disturbances
conducting to the net and net overvoltage watch. Chokes L005 (2000) and L006 (2500/3500)
also limit the electromagnetic disturbances conducting to the net. Auxiliary transformer T002
generates the needed voltages for control cards.

Filter card layout

X6
X1
X7

X8

X5 X2
X4 X3
16
Mastertig 2000 AC/DC Z001
Filter card layout

X3
X1

X15
X7
X9 X5
X11
X13
X19

R3
X24
X25
X16

X22
X18 X23

Mastertig 2500 AC/DC Z002

X19 X2 X15 X21 X9 X8

X6
X7
X1
X20
X4 X11
X5 X10

X14 X22 X16 X17 X18 X12 X13

Mastertig 3500 AC/DC Z002 17

Main circuit cards

Mastertig 2000 AC/DC Z002

The primary rectifier VG102 rectifies the net voltage. The primary choke L001 and smoothing
capacitors CZ213…CZ216 filter the DC voltage. Working capacitors CZ201…CZ212, main
transformer T001 and IGBT-transistor VG101 form the primary inverter. Primary circuit current
is measured by current transformer T004.

Mastertig 2500 AC/DC Z001

The primary rectifier VG101 rectifies the net voltage. Primary choke L001 and smoothing
capacitor C003 filter the DC voltage. Primary inverter´s working capacitors are mounted onto
the main circuit card Z001.

18
Main circuit cards

Mastertig 3500 AC/DC Z001

The primary rectifier VG101 rectifies the net voltage. Primary choke L001 and smoothing
capacitor C002 filter the DC voltage. The primary inverter´s working capacitors are mounted onto
the main circuit card Z001.

Main circuit cards layout

X1

X6
X4
X3

X2

Mastertig 2000 AC/DC Z002 X5 19

 Main circuit cards layout
X8 X6 X7

X9

X2

X1

X3 X5 X4

Mastertig 2500 AC/DC Z001

3/E1 X5 X8

X9 X9 X10 X7 X7

X5

X5

X4
20
Mastertig 3500 AC/DC Z001
Voltage selector switch

Mastertig 2500 AC/DC S003

Voltage selector switch S003 is used to select the correct net voltage (3~ 230, 400, 460 Vac). It
sets the correct transformation ratios for the main transformer T001 and voltages for auxiliary
transformer T002.
Secondary circuit components

Mastertig AC/DCs

Diode cards rectify the main transformer T001´s secondary voltages. The secondary unit
G002´s IGBT-transistors genereate the current type: DC-, DC+ or AC. Control card A003
generates the auxiliary pulse (approx. 400V/ 1ms) needed in AC welding. 21
Secondary circuit components

Mastertig AC/DCs

The shunt resistor R001 is used to measure secondary circuit current. The spark transformer
T003 increases the TIG ignition spark to approx. 10 kV. C001 gives protection against the
TIG ignition spark.

Mastertig 2500W/3500W AC/DC

Reed-relay K001 protects the liquid cooled TIG-torch, in case the cooling method selector switch
is in gas-position.

22
Diode card layout

Cooling unit

Mastertig 2500W AC/DC

The auxiliary transformer T005 generates the 230 Vac supply voltage for the pump motor.
The filter card Z004´s PTC-resistors protect the auxiliary transformer T005, if a wrong supply
voltage is selected by the voltage selector switch S003.

Mastertig 3500W AC/DC

The auxiliary transformer T005 generates the 230 Vac supply voltage for the pump motor.
23
Filter card Z004 layout
X6 X3

X4

X13

X12

X11

X5 X2 X1

Mastertig 2500W AC/DC Z004

Cooling unit control card A005

Coolant temperature-PTC RW301 Pressure watch S002

Too low pressure-warning

lamp
Pump motor control relay K1

Coolant overheat
warning lamp

Power supply from control card A002 Test switch

Liquid-/gas cooling
Control selection switch
Cooling unit start

To Reed-relay K001
GND

Mastertig 2500W/3500W AC/DC A005

24
 Control card A005 layout

X1

K1 X2

Control card A001 (panel) functions

Control cardA001 includes the following functional blocks:

• Processor
• Memories
• Displays
• Panel membrane switches read
• Potentiometers
• Net voltage watch
• Fan control
• Cooling unit control/watch
• Secondary IGBT control
• TIG ignition spark control
• Solenoid valve control
• AC-TIG auxiliary pulse control
• Temperature watch
• Machine size detection
• Torch switch start
• Remote controller set value
• Secondary current and voltage watch

25
Control card A001 connectors
X1/1 Machine size detection (1600/2500)
X1/2 Set value from the remote controller
X1/3 Process selecting from the remote controller
X1/4 Overheat protections (PTC)
X1/5 Machine size detection (2000)
X1/6 Fan control
X1/7 Net voltage watch from the aux. Transformer T002 secondary
X1/8 -
X1/9 Welding current; DC+ or AC positive half cycles
X1/10 Welding current; DC- or AC negative half cycles
X1/11 Welding voltage; DC+ or AC positive half cycles
X1/12 Welding voltage; DC- or AC negative half cycles
X1/13 Net overvoltage watch
X1/14 Control amplifier (N6-A) output
X1/15 TIG-torch switch
X1/16 AC TIG auxiliary pulse control

X2/1 Solenoid valve

X2/2 TIG ignition spark control
X2/3 Set value from A001
X2/4 PWM enable
X2/5 Secondary IGBT control
X2/6 Secondary IGBT control
X2/7 + 16 V
X2/8 + 16 V
X2/9 +5V
X2/10 +5V
X2/11 GND
X2/12 GND
X2/13 Cooling unit start
X2/14 Stop-command from the cooling unit
X2/15 Inverter frequency 18/36 kHz
X2/16 Machine size detection (3500)

26
Control card A002 functions / connectors

Control card A002´s functional blocks:

• PWM-development
• Primary IGBT control
• Current and voltage adjustment loop
• Aux. Voltages development + 5, ± 15, + 16 and + 24 V
• Secondary overvoltage watch
• Primary current limiting circuit
• Net overvoltage and undervoltage watch
• Fan control power stage
• Solenoid valve control power stage
• Cooling unit control power supply

X1/1 Machine size detection (1600/2500)

X1/2 Set value from the remote controller
X1/3 Process selecting from the remote controller
X1/4 Overheat protections (PTC)
X1/5 Machine size detection (2000)
X1/6 Fan control
X1/7 Net voltage watch from the aux. Transformer T002 secondary
X1/8 -
X1/9 Welding current; DC+ or AC positive half cycles
X1/10 Welding current; DC- or AC negative half cycles
X1/11 Welding voltage; DC+ or AC positive half cycles
X1/12 Welding voltage; DC- or AC negative half cycles
X1/13 Net overvoltage watch
X1/14 Control amplifier (N6-A) output
X1/15 TIG-torch switch
X1/16 AC TIG auxiliary pulse control

X2/1 Solenoid valve

X2/2 TIG ignition spark control
X2/3 Set value from A001
X2/4 PWM enable
X2/5 Secondary IGBT control
X2/6 Secondary IGBT control
X2/7 + 16 V
X2/8 + 16 V
X2/9 +5V
X2/10 +5V
X2/11 GND
X2/12 GND
X2/13 Cooling unit start
X2/14 Stop-command from the cooling unit
X2/15 Inverter frequency 18/36 kHz
X2/16 Machine size detection (3500)
27
Control card A002 connectors

X3/1-2 Primary IGBT control

X4/1-2 Primary IGBT control
X5 Aux. Transformer T002 0V
X6 Aux. Transformer T002 13 Vac
X7 Aux. Transformer T002 13 Vac
X8/1 TIG ignition spark control
X8/2 13 Vac
X8/3 TIG-torch start detection
X8/4 + 24 V
X8/5 GND
X9/1-2 Solenoid valve
X9/3-4 Fan
X9/5 Secondary voltage (U2)
X9/6-7 Fan
X9/8-9 Shunt resistor R001
X9/10 Machine size (3500)
X9/12-13 Current transformer T004
X9/14 GND
X9/15 Machine size (1600/2500)

X10/1 Secondary IGBT control

X10/2 +5V
X10/3 Secondary IGBT control
X10/4 - 15 V
X10/5 + 15 V
X10/6 GND
X10/7 Set value from remote controller
X10/8 -
X10/9 TIG/MMA selection from remote controller
X10/10 AC-TIG auxiliary pulse control
X10/11 + 24 V
X10/12 + 15 V
X10/13 + 15 V
X10/14 GND
X10/15 GND
X10/16 -

X11/1 Stop-command from the cooling unit

X11/2 Cooling unit control
X11/3 + 24 V
X11/4 GND
X14/1-6 PTC-resistors
X20/2 Net overvoltage
X20/3 + 15 V
X20/4 GND
X22 Protective earth

28
Control card A002 layout
3,15 AT

X8 X22

X7
X1
X6
X5
X10
X20

R44
X2 Inverter frequency
X14

R119
Max current DC+

X9

X3 R118
Max current DC-
X4 X11

X8 X22

X7
X1
X6
X5
X10
X20
R44
X2 Inverter frequency
X14

X9

X3 R118
Max current
X4 X11

From serial number 985660/L onwards

29
Control card A003 functions / connectors

Control card A003´s functional blocks:

• Secondary IGBT control power stage
• Remote controller connection
• AC-TIG aux. Pulse developement
• OCV circuit

X1/1 Secondary IGBT control

X1/2 +5V
X1/3 Secondary IGBT control
X1/4 - 15 V
X1/5 + 15 V
X1/6 GND
X1/7 Remote controller set value
X1/8 -
X1/9 TIG/MMA selection from remote controller
X1/10 AC-TIG aux. Pulse control
X1/11 + 24 V
X1/12 + 15 V
X1/13 + 15 V
X1/14 GND
X1/15 GND
X1/16 -

X2 AC-TIG aux. Pulse power supply (auxiliary coil)

X3/1,4 Secondary IGBT control
X3/3,6 Secondary IGBT control
X4 AC-TIG aux. Pulse power supply (auxiliary coil)
X5/1,3 Secondary IGBT control
X5/3,5 Secondary IGBT control
X7 Protective earth
X8/1 TIG/MMA selection from remote controller
X8/2 Remote controller potentiometer voltage reference
X8/3 Remote controller potentiometer "slide"
X8/4 Remote controller potentiometer ground
X10 AC-TIG aux. Pulse / OCV circuit DC +
X11 OCV circuit DC -
X12 Main transformer secondary mid-points

30
Control card A003 layout

X8

X7
X5
H1 (DC-)
H2 (DC+/AC)
X3
X1

X11
X4
X2 X12
L1

X8 X3 X5

X7

H1 (DC-) L1
H2 (DC+/AC)

X1

X11

X4
X2 X12

From serial number 980039/L onwards

31
Control card A004 functions / connectors

Control card A004 includes these operational blocks:

• TIG ignition spark development
• TIG-torch start detection

X1/1,3 Spark transformer primary (approx. 1 kV)

X2/1,3 360 Vac from aux. Transformer T002
X3/2 TIG-torch start detection
X3/3 13 Vac
X3/4 + 24 V
X3/5 TIG ignition spark control
X3/6 GND
X4/1,2 TIG-torch start switch

Control card A004 layout

X4 X3

X2

X1

32
Structure

A003 T002

S001
A002

Z001
A001

VG102

M001, M002
T001

L1 GA001

T003

Y001
A004

R001

VG201, VG202 VG101

Z002

Mastertig 2000 AC/DC

33
Structure
A003

S001
A002
Z002
A001
T002

VG101 VG201, VG202

Z001 GA001
C003
L1
T001
T005

S002

Z004

T003

A004
K001

S003

VG103

M001, M002 T004

A005

M003

Mastertig 2500W AC/DC

34
Structure A003

S001
A002 Z002
A001 T002

Y001
VG101 GA001
Z001
L1 M001

T001

C002

S002

T003

K001
A004

VG103

T004

G002

T005 A005

M003

35
Mastertig 3500W AC/DC
Troubleshooting
The machine may be repaired only by a workshop/technician licensed and authorized for the
job!
First do a visual check to find possible damage points, for example loose connectors broken wires
or signs of overheating.
Troubleshooting diagram
PROBLEM
The power source doesn´t start.
Panel lights and displays remain blank.
After startup the fans remain rotating.
Panel not operating.
Not all functions of the panel working
correctly.
The power source won´t start up.
Wrong supply voltage, over or under
voltage signal lamp is on.
Uin Err error message is shown on the
display.
Err 1 error message is shown on the
display.
The net fuse gets burnt during startup.
POSSIBLE CAUSE
Net fuse / fuses have burnt.
A damaged supply cable.
A faulty main switch S001.
A faulty auxiliary transformer T002 or a
bad connection in auxiliary transformer
connectors.
A faulty control card A002.
Bad contact in the flat cable between
function panel and control card A002.
Faulty panel.
Wrong supply voltage has been
selected(ACDC 2500). A phase is
missing.
Power sources output voltage has risen
over 90 V for more than 4 seconds.
A faulty supply cable.
A faulty primary circuit component.
A faulty secondary circuit component.
REMEDY
Check net fuses.
Check the supply phases from connector
X001. Fix/replace the supply cable as
needed.
Check the main switch condition..
Check the auxiliary transformer T002
and the connectors. Fix bad connections
or replace T002 if necessary.
Check the control card A002 fuses.
Replace the A002 if necessary.
Check flat cables and connectors X1 and
X2.
NOTE! RESET THE PANEL, BY
PRESSING DOWN CONTACT-TIG
AND HF-TIG BUTTONS, WHILE
STARTING UP THE POWER
SOURCE BY MAIN SWITCH..
IF SOME PANEL FUNCTION IS NOT
WORKING AFTER RESETTING THE
PANEL, REPLACE THE PANEL
MEMBRANE OR THE PANEL.
Disconnect the power source plug from
the net, and select the correct supply
voltage by selector switch S003 (ACDC
2500 and 2500W). Check the presence
of all supply phases.
Check the condition of the control card
A003.
Check and replace the supply cable as
necessary.
Check the primary side components
(main switch, primary rectifier, primary
IGBT etc.).
Check the diode cards, secondary IGBT
and control card A003).
36
Troubleshooting diagram
PROBLEM
The cooling unit doesn´t work.
The cooling unit doesn´t start by the test
switch.
The missing coolant pressure warning
lamp H001 is on..
The coolant will not circulate by the test
switch SW301.
The coolant doesn´t return to the
reservoir.
TIG HF-ignition doesn´t work.
AC TIG-welding doesn´t work. Th e arc
dies after a short period of welding.
In AC-welding the second half-cycle is
missing. DC+ or DC- method is
inoperative.
POSSIBLE CAUSE
Fuse F002, 2A has burnt.
Faulty aux. Transformer T005.
Faulty control card A005.
Coolant level too low.
A faulty pressure switch S002.
Pressure switch limit (approx.1bar.)
incompatible with the torch.
Pump motor start capacitor C004 faulty.
A faulty control card A005.
The system has an air bubble blocking
the circulation. Coolant level too low.
A leak in the system.
A faulty TIG -torch.
A faulty auxiliary transformer T002.
A faulty control card A004.
A faulty control card A003.
A faulty control card A003.
A faulty secondary unit; IGBT or diode
cards.
REMEDY
Check / replace the fuse as necessary.
Check the aux. Transformer T005
primary and secondary voltages. Check
the filter card Z004 (2500W).
Check the control card A005.
Check the coolant level.
Check the voltage over the pressure
switch from control card A005 between
X2/1 and X2/8; Pressure = 0V, no
pressure = 24V.
Re-adjust the pressure switch limit:
1. Run the pump with the test switch
SW301 during adjustment.
2. After 5 seconds turn the adjustment
screw carefully, until the lamp H001
goes off.
3. Check the result by welding.
Check / replace capacitor.
Check / replace the A005.
Check the coolant level in the reservoir.
Hint: Blow compressed air into the
reservoir. The filler neck can be block
by hand.
Check all hoses and connections in the
system.
Check and fix the TIG-torch
(consumable parts / electrode).
Check the aux. Transformer T002
secondary voltages from control card
A004´s connectors X2/1=0V and
X2/3=360V. Replace T002 as
necessary.
Check the spark on / off -control from
control card A004 connector X3/5.
Check / replace control card A003.
Check if the process is changed on
control card A003. Replace the card as
necessary.
Check / replace secondary unit faulty
components.
37
Net voltage operational limits

Mastertig 2000 Minimum Maximum

230 Vac 165 Vac 270 Vac
Mastertig 2500 Minimum Maximum
230 Vac 175 Vac 270 Vac
400 Vac 300 Vac 460 Vac
460 Vac 340 Vac 530 Vac
Mastertig 3500 Minimum Maximum
400 Vac 365 Vac 460 Vac

Signals between control card A001 (panel) and A002, X1 and X2

Set value from remote controller, voltage on connector X1/2

No remote controller Remote controller minimum Remote controller maximum

38
Process selection from the remote controller, voltage on connector X1/3

TIG-process MMA process

Temperature watch, voltage on connector X1/4

Temperature watch in room temperature (approx.. + 20º C)

Fan control, voltage on connector X1/6

Fans on

Info of welding current (DC+ and AC pos. half-cycles), voltage on X1/9

DC+ 10 A, MMA DC+ 200 A, MMA DC+ 350 A, MMA 39

Info of welding current (DC+ and AC pos. half-cycles), voltage on X1/9

AC 10 A, MMA AC 200 A, MMA AC 350 A, MMA

Info of welding current (DC+ and AC pos. half-cycles), voltage on X1/11

+ 15 V, MMA + 30 V, MMA + 70 V, MMA

15 Vac, MMA 30 Vac, MMA

Net overvoltage watch, voltage on connector X1/13

Net voltage OK Net overvoltage

40
Torch start switch detection, voltage on connector X1/15

Torch start switch open

Torch start switch closed

41
AC TIG-welding auxiliary pulse control, voltage on connector X1/16

AC TIG-welding auxiliary pulse control

AC TIG-welding auxiliary pulse control

42
Solenoid valve Y001 control, voltage on connector X2/1

Solenoid valve open

TIG HF-ignition spark control, voltage on connector X2/2

TIG ignition spark control (if the arc is not on immediately, then controls will be on in 10 ms. Intervals for 2 seconds)

Set value from control card A001 (panel), voltage on connector X2/3

10 A 100 A 200 A 350 A

43
PWM-control enabling, voltage on connector X2/4

PWM enabled PWM disabled

Secondary IGBT control, voltage on connector X2/5

DC+ DC-

AC 50 Hz, MMA

44
AC 200 Hz, TIG
Secondary IGBT control, voltage on connector X2/5

Balance -70, TIG

Balance +70, TIG

Cooling unit control, voltage on connector X2/13

Cooling unit is off Cooling unit is on

45
Cooling unit monitorings, voltage on connector X2/14

Cooling OK Error, stop -command to cooling unit

Inverter frequency selection, voltage on connector X2/15

36 kHZ 18 kHZ

Measurings from control card A002 connector X8

46
TIG ignition spark control, voltage on connector X8/1

TIG ignition spark control (if the arc is not on immediately, then the controls are on in 10 ms. Intervals for 2 s.)

Torch start switch detection, voltage on connector X8/3

Torch start switch open

Torch start switch closed

47
Measurings from control card A002 connector X9

Solenoid valve Y001 control, voltage on connector X9/1-2

Solenoid valve open

Fan control, voltage on connector X9/3-4, 6-7

Fan on

Fan ”soft start”

48
Information of secondary side voltage, voltage on connector X9/5

Idling DC+, MMA

Information of primary side current, voltage on connector X9/12-13

100 A 200 A

350 A

49
Measurings from control card A002 connector X10

Secondary IGBT control, voltage on connector X10/1

DC+ DC- AC, MMA / Idling

AC 50 Hz, MMA AC 200 Hz, TIG

50
Secondary IGBT control, voltage on connector X10/1

Balance -70, TIG Balance +70, TIG

Set value from remote controller, voltage on connector X10/7

Without controller Minimum Maximum

Process selection from remote controller, voltage on connector X10/9

MMA TIG

51
AC TIG auxiliary pulse control, voltage on connector X10/10

AC-TIG auxiliary pulse control

Measurings from control card A002 connector X11

Cooling unit monitorings, voltage on connector X11/1

Cooling OK Error, stop -command to power source 52

Cooling unit control, voltage on connector X11/2

Cooling unit is not on Cooling unit is on

Measurings from control card A002 connector X20

Net overvoltage measuring, voltage on connector X20/2

Net voltage OK Net overvoltage, stop -command to power source

53
Measurings from control card A003 connector X3

Secondary IGBT control, voltage on connector X3/1-4

DC+ DC-

AC, MMA / idling

AC 50 Hz, MMA

54
Secondary IGBT control, voltage on connector X3/1-4

AC 200 Hz, TIG

Balance -70, TIG

Balance +70, TIG

55
Measurings from control card A003 connector X8

Remote controller voltage reference, voltage on connector X8/2-4

Set value from remote controller, voltage on connector X8/3-4

Min Max

56
Process selection from remote controller, voltage on connector X8/1-4

MMA TIG

Mastertig 2000 AC/DC inverter controls

IGBT gate pulses, voltage on connector X3/1-2 (A002)

Mastertig 2000 AC/DC

IGBT gate pulse control on MMA / idling

57
IGBT gate pulses, voltage on connector X3/1-2 (A002)

Mastertig 2000 AC/DC

IGBT gate pulse control 10 A

Mastertig 2000 AC/DC

IGBT gate pulse control 50 A

58
IGBT gate pulses, voltage on connector X3/1-2 (A002)

Mastertig 2000 AC/DC

IGBT gate control 100 A

Mastertig 2000 AC/DC

IGBT gate control 106 A (Note! Frequency!)

59
IGBT gate pulses, voltage on connector X3/1-2 (A002)

Mastertig 2000 AC/DC

IGBT gate control 160 A

Main transformer T001 primary voltage

Mastertig 2000 AC/DC

60
T001 primary voltage 10 A
Main transformer T001 primary voltage

Mastertig 2000 AC/DC

T001 primary voltage 50 A

Mastertig 2000 AC/DC

T001 primary voltage 100 A

61
Main transformer T001 primary voltage

Mastertig 2000 AC/DC

T001 primary voltage 106 A (Note! Frequency!)

Mastertig 2000 AC/DC

T001 primary voltage 160 A

62
Voltage after the diode cards

Mastertig 2000 AC/DC

After the diode card 10 A

Mastertig 2000 AC/DC

After the diode card 50 A 63

Voltage after the diode card

Mastertig 2000 AC/DC

After the diode card 100 A

Mastertig 2000 AC/DC

After the diode card 106 A (Note! Frequency!) 64

Voltage after the diode cards

Mastertig 2000 AC/DC

After the diode card 160 A

Secondary voltage U2 using a low-pass filter

10 kΩ
TIG
22 nF U2

65
Secondary voltage U2 using a low-pass filter

Mastertig 2000 AC/DC

AC 10 A 50 Hz,MMA

Mastertig 2000 AC/DC

AC 100 A 50 HZ, MMA

66
Secondary voltage U2 using a low-pass filter

Mastertig 2000 AC/DC

AC 160 A 50 Hz, MMA

Mastertig 2000 AC/DC

AC 10 A 100 Hz, TIG (Balance 50/50, balance automatics ON)

67
Secondary voltage U2 using a low-pass filter

Mastertig 2000 AC/DC

AC 50 A 100 Hz, TIG

Mastertig 2000 AC/DC

AC 100 A 100 Hz, TIG

68
Secondary voltage U2 using a low-pass filter

Mastertig 2000 AC/DC

AC 160 A 100 Hz, TIG

Mastertig 2000 AC/DC

AC 200 A 100 Hz, TIG

69
Mastertig 2500 AC/DC inverter controls

IGBT gate pulses, voltage on connector X3/1-2 (A002)

Mastertig 2500 AC/DC

IGBT gate control 10 A

Mastertig 2500 AC/DC

70
IGBT gate control 100 A
IGBT gate pulses, voltage on connector X3/1-2 (A002)

Mastertig 2500 AC/DC

IGBT gate control 106 A (Note! Frequency!)

Mastertig 2500 AC/DC

IGBT gate control 250 A

71
Voltage over a lower IGBT

Mastertig 2500 AC/DC

Voltage over the lower IGBT 10 A

Mastertig 2500 AC/DC

Voltage over the lower IGBT 100 A

72
Voltage over the lower IGBT

Mastertig 2500 AC/DC

Voltage over the lower IGBT 250 A

Secondary voltage U2 using a low-pass filter

10 kΩ
TIG
22 nF U2

73
Secondary voltage U2 using a low-pass filter

Mastertig 2500 AC/DC

AC 10 A 50 Hz, MMA

Mastertig 2500 AC/DC

AC 100 A 50 Hz,MMA
74
Secondary voltage U2 using a low-pass filter

Mastertig 2500 AC/DC

AC 250 A 50 Hz, MMA

Mastertig 2500 AC/DC

AC 10 A 100 Hz, TIG (Balance 50/50, balance automatics ON) 75

Secondary voltage U2 using a low-pass filter

Mastertig 2500 AC/DC

AC 100 A 100 Hz, TIG

Mastertig 2500 AC/DC

AC 250 A 100 Hz, TIG

76
Mastertig 3500 AC/DC inverter controls

IGBT gate pulses, voltage on connector X3/1-2 (A002)

Mastertig 3500 AC/DC

IGBT gate control on idle

Mastertig 3500 AC/DC

77
IGBT gate control 10 A
IGBT gate pulses, voltage on connector X3/1-2 (A002)

Mastertig 3500 AC/DC

IGBT gate control 100 A

Mastertig 3500 AC/DC

IGBT gate control 106 A 78

IGBT gate pulses, voltage on connector X3/1-2 (A002)

Mastertig 3500 AC/DC

IGBT gate control 200 A

Mastertig 3500 AC/DC

IGBT gate control 350 A 79

Secondary voltage U2 using a low-pass filter

Mastertig 3500 AC/DC

AC 10 A 50 Hz, MMA

Mastertig 3500 AC/DC

AC 100 A 50 Hz, MMA

80
Secondary voltage U2 using a low-pass filter

Mastertig 3500 AC/DC

AC 200 A 50 Hz, MMA

Mastertig 3500 AC/DC

AC 350 A 50 Hz, MMA

81
Secondary voltage U2 using a low-pass filter

Mastertig 3500 AC/DC

AC 50 A 100 Hz, TIG (Balance 50/50, balance automatics ON)

Mastertig 3500 AC/DC

AC 100 A 100 Hz, TIG 82

Secondary voltage U2 using a low-pass filter

Mastertig 3500 AC/DC

AC 200 A 100 Hz, TIG

Mastertig 3500 AC/DC

AC 350 A 100 Hz, TIG 83