Service training

MASTER MASTERTIG
MLS1600 MLS 2000
 General
Master 1600 MLSTM and Mastertig 2000 MLSTM are 1-phase MMA- and TIG-
welding suitable inverter power sources for DC-welding. Primary inverter is
based on IGBT-technology and the operating frequency is 65 kHz in all power
sources.

Master 1600 MLSTM and Mastertig 2000 MLSTM power source functions are
controlledby a microcontroller, so all welding features are carried out programmably.
Also the control panels have microprocessors, except the MEL panel.

Mastertig 2000 MLSTM is not compatible with the Mastercool 10 cooler.

Master MLSTM and Mastertig MLSTM powersources work without panels also, as MMA
power souces operated with a remote controller.
 R002 / S001
Overvoltage protection / main switch

Varistor R002 works as an overvoltage protection against low energy voltage peaks.
ATTENTION! Varistor R002 is mounted before the mainswitch S001.
 L001
Primary choke

The primary choke increases the power factor.

With maximum current the power factor is approx. 0,75.
 L002, L006 ja L007

The choke L002 decreases the current through IGBT opposite diodes and IGBT power losses.
The chokes L006 and L007 decrease secondary diode power losses and voltage stress.
 T001
Main transformer

Main tranformer T001 has two parallel primary coils and two parallel plus two
series connected secondary coils. There are also two auxiliary coils in the secondary
for voltage reserve (cellulose stick). The transformation ratio is 2,5.
 L008
Voltage reserve circuit chokes

The chokes in the voltage reserve circuit limit the auxiliary coil current to
approximately 20 A.
 L003
Secondary choke

The secondary choke L003 smoothens the secondary current waveform.

Mastertig 2000 MLSTM power source has no secondary choke.
 RC001 ja C001
Secondary RFI filter

The varistors and capacitors decrease radio frequency interference (RFI) and protect
the power source from the TIG ignition spark.
 RT102 ja RT101
Overheat protection

(Main transformer) (Secondary rectifier unit)

The main transformer T001 and the secondary rectifier unit are protected against
overheating by PTC resistors.
 M001 ja M002
Cooling fans

The cooling air flows from the back of the power source towards the front (ICSTM).
 L004, L005 ja L009
Interference protection

(Control cable connection, remote controller)

The chokes are meant to decrease the interferences caused by the TIG ignition spark.
The choke L005 also decreases electromagnetic interferences conducted to
the electric network (EMI).
 R001
Shunt resistor

The shuntresistor measures secondary circuit current. The value of the shunt
resistor is 200 µV / A.
 T002
Spark transformer

The spark transformer primary has one turn and the secondary has eleven turns.
The spark tranformer primary voltage is approx. 1 kV.
 Y001
Solenoid valve

The solenoid valve is of traditional type (9563002) and controlled by the micro controller
through control card A004.
 Z001
Main circuit card

• EMI filter
• Primary rectifier
• Smoothing capacitors
• Power stage
• Dampening circuit (R+C)

Connectors
XZ116 and XZ117 Mains voltage 230 VAC
XZ105 and XZ106 Power supply card A002 power supply
XZ101 and XZ104 IGBT gate control
XZ109 and XZ110 Primary choke
 XZ117
XZ116
R1 R17

C15

L1
C1 C13
XZ113

C14

V12
XZ110 L001

XZ109
L2

C2...C5
Z001

XZ107
Main circuit card

R2 R3
XZ108

C6...C8 C9...C11

XZ105
C16
T001

XZ106
L002 V18...V22 V13...V17

R7
V2...V6
V7...V11

R5,R6,R8...R10 R11,R12,R14...R16

C12
R4 R13
XZ102

XZ104
XZ103
XZ101
 Z001
EMI-filter

L001
XZ101

R11,R12,R14...R16
XZ113

XZ110

XZ109

R13
L2
XZ116
C13

C9...C11

V13...V17
L1
R17

R3
C15

C14
C1

V7...V11

C2...C5
XZ102

C16

C12
R1

V18...V22
C6...C8
R2

R4
XZ117
V2...V6
V12 XZ103

R5,R6,R8...R10
XZ107

XZ108

XZ105

XZ106

R7
XZ104

L002
EMI filter reduces electromagnetic interference conducting T001

to the electric network (EN 50199).

 Z001
Primary rectifier

L001
XZ101

R11,R12,R14...R16
XZ113

XZ110

XZ109

R13
L2
XZ116
C13

C9...C11

V13...V17
L1
R17

R3
C15

C14
C1

V7...V11

C2...C5
XZ102

C16

C12
R1

V18...V22
C6...C8
R2

R4
XZ117
V2...V6
V12 XZ103

R5,R6,R8...R10
XZ107

XZ108

XZ105

XZ106

R7
XZ104

L002
T001

Primary rectifier V12 (35 A) rectifies the mains voltage to intermediate DC.
Intermediate circuit DC varies between 260…380 V.
 Z001
Smoothing capacitors

L001
XZ101

R11,R12,R14...R16
XZ113

XZ110

XZ109

R13
L2
XZ116
C13

C9...C11

V13...V17
L1
R17

R3
C15

C14
C1

V7...V11

C2...C5
XZ102

C16

C12
R1

V18...V22
C6...C8
R2

R4
XZ117
V2...V6
V12 XZ103

R5,R6,R8...R10
XZ107

XZ108

XZ105

XZ106

R7
XZ104

L002
T001

Capacitors C2…C5 form an energy reserve, which is needed when the mains voltage is
lower than the intermediate DC.
 Z001
Power stage

L001
XZ101

R11,R12,R14...R16
XZ113

XZ110

XZ109

R13
L2
XZ116
C13

C9...C11

V13...V17
L1
R17

R3
C15

C14
C1

V7...V11

C2...C5
XZ102

C16

C12
R1

V18...V22
C6...C8
R2

R4
XZ117
V2...V6
V12 XZ103

R5,R6,R8...R10
XZ107

XZ108

XZ105

XZ106

R7
XZ104

L002
T001

The power stage is a traditional half-bridge, where intermediate circuit DC is halved by working
capacitors (C6…C11).The parallel connected IGBTs (V2…V11) are used as a power switch.
 Z001
Dampening circuit

L001
XZ101

R11,R12,R14...R16
XZ113

XZ110

XZ109

R13
L2
XZ116
C13

C9...C11

V13...V17
L1
R17

R3
C15

C14
C1

V7...V11

C2...C5
XZ102

C16

C12
R1

V18...V22
C6...C8
R2

R4
XZ117
V2...V6
V12 XZ103

R5,R6,R8...R10
XZ107

XZ108

XZ105

XZ106

R7
XZ104

L002
T001

The dampening circuit (R+C) reduces voltage stress of the IGBT and LC vibration
after the IGBT has closed.
 Z001
Layout

EMI filter Smoothing capacitors (9755615) Work capacitors

Rectifier unit V12 (9750191) IGBTs, series resistors and opposite diodes
(IGBT set 4301810 incl. 5 pcs. IGBT + series resistors)
 Z001
Layout

XZ113 XZ109 XZ106 XZ108 XZ105

XZ116 XZ116 XZ110 XZ104 XZ103 XZ101 XZ102 XZ107

 Z001
Function
260…380 VDC

When the both IGBTs are non-conductive,

no power is transferred.

When the upper IGBT is conductive, the

main transformer primary side has a positive
voltage (U1) and when the lower IGBT is
conductive the voltage (U1 ) is negative.
U1 Z001

T001
The power is adjusted by changing the
conductivity timing of the IGBTs (PWM).
 Z001
Gate pulse
260…380 VDC

Z001

T001
 Z001
Gate pulse
260…380 VDC

Z001

T001
 Z001
Main transformer primary voltage
260…380 VDC

U1 Z001

T001
 Z001
Main transformer primary voltage
260…380 VDC

U1 Z001

T001
 Z002
Diode card

• Secondary rectifying
• Voltage reserve circuits
• Machine size coding
• OCV circuit
• Dampening circuits

Connectors
XZ7 Shunt resistor negative (R001)
XZ1 and XZ6 Voltage reserve circuits chokes (L008)
XZ8 and XZ9 Voltage reserve circuits auxiliary coils
(T001) and chokes (L008)
XZ11 and XZ10 Spark generator power supply
XZ2 and XZ4 Secondary choke (L001)
XZ12, XZ13 and Machine size coding
XZ14
XZ3 and XZ5 Main transformer secondary side
 Z002
U RZ1
Secondary rectifying
CZ1 RZ3

VZ1
XZ1

CZ2 RZ4

XZ8 U RZ2

VZ3

XZ11 VZ4 Full wave rectifier rectifies the secondary

XZ3
VZ6
current.
VZ2

VZ5
Varistors RZ2 and RZ7 (175 V) are
T001

VZ7
XZ4 protection against TIG ignition spark.
VZ8

XZ5
VZ9 XZ2 Dampening circuits (R+C) reduce voltage
RZ11

VZ12
stress for diodes.
RZ12

RZ13

+
CZ5

RZ9

XZ10 VZ10

U RZ7 +
RZ10
CZ4
XZ12

XZ14

XZ13

XZ9
CZ3 RZ5

VZ11
XZ6 XZ7
CZ6 RZ6

U RZ8
 Z002
U RZ1
Voltage reserve circuits
CZ1 RZ3

VZ1
XZ1

CZ2 RZ4

XZ8 U RZ2 Voltage reserve circuits increase secondary

VZ3
voltage on low currents(I2 < 40 A).
XZ11 VZ4

VZ6
XZ3
VZ2
Diodes VZ1 and VZ11 (30 A, 600 V)
VZ5
rectify the voltage in main transformer
T001

VZ7
XZ4 auxiliary coils.
VZ8

VZ9 XZ2
XZ5
Varistors RZ1 and RZ8 (230 V) give
RZ11

VZ12
protection against the TIG ignition spark.
RZ12

RZ13

+
CZ5

RZ9

XZ10 VZ10

U RZ7 +
RZ10
CZ4
XZ12

XZ14

XZ13

XZ9
CZ3 RZ5
Dampening circuits (R+C) decrease
VZ11
voltage stress on diodes.
XZ6 XZ7
CZ6 RZ6

U RZ8
 Z002
U RZ1
Machine size coding
CZ1 RZ3

VZ1
XZ1

CZ2 RZ4

XZ8 U RZ2 RZ5 (0Ω) RZ4(0Ω) Machine size

VZ3 Off Off
XZ11 VZ4
Off On 160/ 200 A
XZ3
VZ6
On Off 250/ 300 A
VZ2
On On 350/ 400 A
VZ5

VZ7
XZ4
VZ8

RZ13
RZ12
XZ5
VZ9 XZ2
RZ11

VZ12
RZ12

RZ13

+
CZ5

RZ9

XZ10 VZ10

U RZ7 +
RZ10
CZ4
XZ12

XZ14

XZ13

XZ9
CZ3 RZ5

VZ11
XZ6 XZ7 X10/7 X10/8 X10/10
CZ6 RZ6

U RZ8
To the microcontroller (A001)
 Z002
U RZ1
OCV circuit
CZ1 RZ3

VZ1
XZ1

CZ2 RZ4

XZ8 U RZ2

VZ3
In no-load situation the power source
XZ11 VZ4
controls the secondary voltage and
XZ3
VZ6
sets the pulse ratio (PWM) to minimum.
VZ2

VZ5
On minimum pulse ratio the main
VZ7
XZ4 transformer magnetizing current is low
VZ8
and tranformer losses are low also.
XZ5
VZ9 XZ2
RZ11

VZ12
RZ12

RZ13

+
CZ5

RZ9

XZ10 VZ10

U RZ7 +
RZ10
CZ4
XZ12

XZ14

XZ13

XZ9
CZ3 RZ5

VZ11
XZ6 XZ7
CZ6 RZ6

U RZ8
 Z002
Layout

XZ1 XZ3 XZ5 XZ6 XZ8

XZ9
XZ10
XZ11
XZ12

XZ2 XZ4 XZ7 XZ14 XZ13

Diode set 4301800 incl. 6 x diode 30 A, 600 V

 A001
Control card

• Microcontroller ST72334N4
• PWM-development (PWMOD UC3846)
• Current and voltage adjustment loop
• IGBT gate control
• Shunt amplifier
• Secondary voltage control
• Primary side overcurrent
limiter circuit (Z004)
• PWM-measuring (A002)
• Auxiliary voltage control
• Reset-generator
• Temperature control
• Microcontroller I/O expansion
• Remote controller connector
(X1) protection
• Buses (SPI, ISP ja SCI)
• MEL mma panel control
 A001
Control card
Microcontroller ST72334N4
 A001
Shunt amplifier

Mikrokontrolleri ST72334N4 2 X12/6

14

R001
6
AIN1
3 X12/12

N1

29
PF4

V7

N4
The shunt amplifier amplifies the shunt voltage. The microcontroller sets the amplification
through FET V7. Amplification on low current levels (I2 < 42A) is approx. 400-times and on
high current levels (I2 > 42A) approx. 50-times.
 A001
IGBT gate control

X2/2
+ 16 V
V32 V33
T3

V14

H1
PWMOD X2/1
X1/2
UC3846
11
A out

V29 V34

V15

H2
14
B out X1/1

N2

PWM-circuit N2 produces signals, that are amplified in the gate buffer. Control transformer T3
provides the primary-secondary side separation. Leds H1 and H2 indicate the gate pulses.
 A001
IGBT gate control

X2/2

V14
H1

X2/1
X1/2

V15
H2

X1/1
 A001
IGBT gate control

X2/2

V14
H1

X2/1
X1/2

V15
H2

X1/1
 A001
IGBT gate control

X2/2

V14
H1

X2/1
X1/2

V15
H2

X1/1
 A001
IGBT gate control

X2/2

V14
H1

X2/1
X1/2

V15
H2

X1/1
 A001
Secondary voltage control circuit
+ DIX

X10/9
+5V
+5V
PWMOD

200k
R113
UC3846

ST72334N4
R114

R96 COMP 7
R115 COMP 5 1
SHUT- 16 2 220k 6 +5V

10k
DOWN 4 1u
C83
V26
+5V N3
N3 +5V
220k
R91

COMP 9 + 1,8 V C80

R90
14
R147 27
11 COMP 8 33u
13 PF2
V27
10
220k

100k
N3

R111
R89

N2 V28
H3
R83

N3

N4
The control circuit stops the power source, if the secondary voltage rises above
100 VDC (norm=113 VDC) for 0,3 seconds. During the TIG ignition spark the control
circuit delay is extended to 4 seconds. TIG ignition spark is an on/off-signal from
microcontroller pin 27.
After the control circuit has functioned, the power source must be reseted with the main switch!
 A001
Primary side overcurrent limiter circuit

PWMOD +5V
UC3846
X16
Z004
R210
X10/11
R76

R186

R187
V22

V44

R206
1 X10/12 X17
C/S
C53

R188

R189
R208
X10/13
V36
C118

X15

V45

R207
R192

R209
R193

N2

The main transformer primary current measuring protects the IGBT transistors.
The indicator circuit limits the IGBT peak current to a safe level (also when malfunctioning).
The maximum peak current varies a bit depending on the pulse ratio (80-110 A).
 Z004
Current transformer card

X16
Z004

R186

R187
X17

R188

X15 R189

The current transformer separates the measuring circuit galvanicly from the primary.
 A001
Auxiliary voltage control (+ 16 V)
+5V

C127
R170
PWMOD
UC3846
R169
+5V

R171
R167 COMP 7
SHUT- 16 1
DOWN 6
+ 16 V
N5-B
N2

R185

C116
R203
The control circuit stops the power source, if the aux. voltage (+16 V) is < + 12,5 V.
 A001
Temperature control
+5V

+5V

C123
R216
PWMOD
UC3846
R205

R221
R217
R166 COMP 9 X3/1
SHUT- 16 14

C125
DOWN 8 X3/2
+5V
N5-C X4/1
N2
R202

RT101 PTC 150 C

+t
R216
Through the shift register D1
X4/2
to the microcontroller N4.
C105

X5/1

C122
R215

+t
RT102 PTC 120 C

X5/2
 A001
Microcontroller I/O expansion
Jumpers

Jumper Closed Open

X18 Normal OCV VRD option ( 10 V)*
X19 - -
X20 OCV 80 V (MEL) OCV 40 V (MEL)
X21 - -

* Requires an auxiliary card

 A001
Remote
+ 24 V
control connector (X1) protection
R38

R26
+ 24 V
t
Z003
V2 12/9 L004
V1 C26 A
GND

V3

R9
12/4
R1 C29 B
+5V +5V (DATA)

t
C28
12/10 C
+24 V
V24

V21
R61 R49
12/2
C37 D
R63 R62
Foot pedal detection / start
12/5 E
C31
Remote control potentiometer
V25

V20

12/11
C C30 F

+ 16 V C27
12/3 G
+5V
R25

R24

R37
D
t
V12
+5V
V11
V13

Remote controller lines are protected against TIG spark and ± 100 V voltages.
Measurement lines are also protected with serial resistors and diodes. PTC resistors
limit power lines (+ 5 V/ + 24 V) current.
 A001
Remote controller connector
X12/2 Foot pedal

Without a foot pedal A foot pedal connected Foot pedal start

 A001
Remote controller connector
X12/5

Without a remote controller Remote controller min. Remote controller max.

 Z003
Remote controller connection (X1) protection

A A
B B
C C
D D
E E
F F
G G

X2
X003
(- DIX)

Filter card Z003 gives protection against the TIG ignition spark disturbances.
 A001
Bus connections

Control card A001 (Microcontroller ST72334N4) has three (four) buses:

SCI (Serial Communication Interface)

SCI-bus provides communication between an external device (for example a PC) and
the power source (RS232).
SPI (Serial Peripheral Interface)
SPI-bus provides communication between the power source microcontroller and the panel
microcontroller (62,5kbits/s.).
ISP (In-Situ Programming)
ISP-bus is used to read/write the data of the flash memory or the eeprom.

MEL mma panel has no microcontroller, so the power source microcontroller

controls it via the parallel bus.
 A001
Connectors
Connector Signal
X1/1-2 IGBT gate control
X2/1-2 IGBT gate control
X3/1-2 Short circuit loop
X4/1-2 Main transformer PTC (RT101)
X5/1-2 Secondary rectifier PTC (RT102)
X8/1-2 Fan
X9/1-2 Fan

Connector X10 Signal

1 + 24 V
2 + 16 V
3 +5V
4 Ground
5 UDC measuring
6 PWM measuring
7 Machine size
8 Machine size
9 Secondary voltage
10 Ground
11 Primary current measuring
12 Ground
13 Primary current measuring
 A001
Connectors

X6 Connector to panel
1 MMA ignition pulse potentiometer
2 Welding dynamica potentiometer
3 Set value potentiometer
4 Switces/display selection, MEL
5 Display selection, MEL
6 MISO (Master In Slave Out), SPI
7 Display control, MEL
8 AKC, SPI-check / Local/remote control selection, MEL
9 Display selection, MEL
10 Display control, MEL
11 Display control, MEL
12 SCK (Clock signal from panel), SPI
13 Display control, MEL
14 MOSI (Master Out Slave In), SPI
15 +5V
16 Ground
 A001
Connectors

X7 Connector to connection card A004

1 TIG ignition spark control
2 Solenoid valve control
3 -
4 Gun start switch
5 -
6 -
7 -
8 SW1 (Gun auxiliary switch)
9 SW2 (Gun auxiliary switch)
10 Gun potentiometer
11 -
12 -
13 +5V
14 + 24 V
15 Ground
16 Ground
 A001
Connectors

X11 Connector to ISP and SCI buses

1 Ground
2 Data signal, ISP
3 Ground
4 Clock signal, ISP
5 Enabled signal, ISP
6 Resetsignal, ISP
7 +5V
8 Select signal, ISP
9 Transmitted data, SCI
10 Received data, SCI

Connector Signal
X13 Arc on/off signal
X14 Arc on/off signal
 A001
Connectors

X12 Connector to the foot pedal

1 -
2 Foot pedal detection/start
3 +5V
4 (Data)
5 Remote controller/foot pedal potentiometer
6 Current information from the shunt resistor
7 Shielding ground
8 -
9 Ground
10 + 24 V
11 -
12 Ground
 A001
Layout
X5 X9
X8
X4
X3
X10

X6

H3
X11

Jumpers
X18…21
H1
H2

X1
X2
X12 R51 X7
(Inverter frequency)
 A004
TIG connection card

• TIG-torch connection
• Solenoid valve control
• TIG ignition spark control
 A004
Torch connection
+ 24 V

+t
R18

R2
R15
+5V
C11

C19

V10
R26

R20

C16
C28

C23
C7

V15
X5/1

V17
V5

V4

V2
C10

R8 R9
X1/8 C6
SW1 C9
X5/2

R5 R6
X1/9 C5
SW2 X5/3
C15

R3 R4
X1/4
Torch start X5/4
C4

C14

Torch X1/10
R13 R12
C3
potentiometer C13
X5/5
X5/1

R11 R10
Water cooled X1/7 C2
X5/6
torch detection C12

+ 24 V

V18
R21

R23

R17

V6

V9

V8

V1
C22

C24

C18

C1
X5/7
L1

C17

+t

R7
R16

R14
V3

+5V

V7
V11

C20

Torch connection is protected against TIG ignition spark and ± 100 V voltages.
 A004
Torch connection

TTC torch connection.

 A004
Solenoid valve control

+ 24 V

X4/1

C27
V16
Solenoid valve
X4/2

R24 V14
Control X1/2

R25

Control card A001 microcontroller controls the solenoid valve via FET V14.
 A004
TIG ignition spark control

X1/1

X2/1

X3/1

X2/2

X3/2
+ 24 V

+t

R27
C19

V12
K1
R19

V13
R22

Control card A001 microcontroller controls the spark generator via relay K1.
 A004
Connectors
X1 Connector to control card A001
1 TIG ignition spark control
2 Solenoid valve control
3 -
4 TIG torch start
5 -
6 -
7 -
8 TIG torch auxiliary switch (SW1)
9 TIG torch auxiliary switch (SW2)
10 TIG torch potentiometer
11 -
12 -
13 +5V
14 + 24 V
15 Ground
16 Ground

Connector Signal
X2/1-2 Spark generator power supply from the main tranformer T001
X3/1-2 Spark generator power supply
 A004
Connectors
X5 Connector to the TIG torch connection
1 Ground
2 TIG torch auxiliary switch (SW1)
3 TIG torch auxiliary switch (SW2)
4 TIG torch start
5 TIG torch potentiometer
6 -
7 +5V
8 -
9 -
10 -
11 -
12 -

Connector Signal
X4/1-2 Solenoid valve control
 A004
Layout

X6 X1

X4
X5 X3
X2

L1 K1
A003
Spark card

• Voltage increasing circuit

• Spark generator
• Auxiliary voltage generating
• Spark generator control

Connector Signal
X1 and X2 Spark generator power supply
X3 and X4 Spark tranformer primary side
 A003
R9

C4 C2
R2 R3 R1 C11
X1 X3
L1

V1
V4

V3

V2

C6

R4
X2

C5 C2 R7 R6 R8

C12
C1

R10
X4
R11 R20
9 COMP
R5

14
V7 R14 8

N1-C

C7

C8
C10
C9
V5

V8

R21

R18
5 COMP
2
R19 4
V6

N1-A C13
R16
R12

R13 R17

V9
7 COMP
1
6 V11 V10

R15
C15

N1-B
R22

11 COMP
13
10
C14

N1-D
 A003
Layout
V10 L1 X3 X4

R21
Spark voltage
adjustment 8…11 kV

X2

X1
 Master 1600 MLS
Layout

S001
Main switch

A001 L005
Control card
R002
VDR
L004

A002
Power supply card
Z001
Main circuit card
 Master 1600 MLS
Layout
T001Main tranformer

Z004
Current transformer card

L008
Voltage reserve
circuit chokes
M001

R001
Shunt
M002

L001 Z002 L003

Prim. choke Diode card Sec. choke
 Mastertig 2000 MLS
Layout

S001
Main switch

A001 L005
Control card
R002
VDR
A004
TIG connection card

A002
Power supply card
Z001
Main circuit card
 Mastertig 2000 MLS
Layout
T001 Main tranformer

Z004
Current tranformer card

Y001
Solenoid valve L008
Voltage reserve
circuit chokes
M001

A003
Spark card

R001
Shunt
M002

L001 Z002 T002

Prim. choke Diode card Spark tranformer