Kemppi MASTERTIG AC/DC 2500W Service Manual

Troubleshooting diagram
PROBLEM POSSIBLE CAUSE REMEDY
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.
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.
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.
TIG HF-ignition doesn´t work. A faulty TIG -torch.
A faulty auxiliary transformer T002.
A faulty control card A004.
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.
AC TIG-welding doesn´t work. Th e arc
dies after a short period of welding.
A faulty control card A003. Check / replace control card A003.
In AC-welding the second half-cycle is
missing. DC+ or DC- method is
inoperative.
A faulty control card A003.
A faulty secondary unit; IGBT or diode
cards.
Check if the process is changed on
control card A003. Replace the card as
necessary.
Check / replace secondary unit faulty
components.
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Kemppi MASTERTIG AC/DC 2500W Specifications

General

Brand	Kemppi
Model	MASTERTIG AC/DC 2500W
Category	Welding System
Language	English