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Contents
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Table of Contents
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Troubleshooting
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Bookmarks
Quick Links
MasterTig
MLS 2300 ACDC
EN
Operating manual • English
FI
Käyttöohje • Suomi
SV
Bruksanvisning • Svenska
NO
Bruksanvisning • Norsk
DA
Brugsanvisning • Dansk
DE
Gebrauchsanweisung • Deutsch
NL
Gebruiksaanwijzing • Nederlands
FR
Manuel d’utilisation • Français
ES
Manual de instrucciones • Español
PL
Instrukcja obsługi • Polski
RU
Инструкции по эксплуатации • По-русски
ZH
操作手册 • 中文
PT
Manual de utilização • Português
IT
Manuale d’uso • Italiano
Summary of Contents for Kemppi MLS 2300 ACDC
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Contents
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Table of Contents
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Bookmarks
Quick Links
Service manual
Mastertig MLS 2300 ACDC
Version 1.3.1
1
Related Manuals for Kemppi MLS 2300 ACDC
Summary of Contents for Kemppi MLS 2300 ACDC
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Page 1: Service Manual
Service manual Mastertig MLS 2300 ACDC Version 1.3.1…
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Page 2: Technical Data
Technical data Connection voltage, 1~ 50/60 Hz 230 V ± 15% Loadability TIG 40% ED 230 A / 19,2 V (5,7 kVA) 60% ED 200 A / 18,0 V (4,8 kVA) 100% ED 170 A / 16,8 V (3,9 kVA) Loadability MMA 40% ED 180 A / 27,2 V (6,0 kVA)
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Page 3: User Interface
User interface Gas connector for TIG torch Welding current connection (negative) Operation panel Remote controller connection TIG -torch control connection Welding current connection (positive) Main switch Gas connector…
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Page 4: Setup Functions
Setup functions Entering the advanced setup press and hold the setup and Return buttons at the same time. Changing the level press Setup button shortly The upslope time depends on the welding current Welding current upslope time * The upslope time is fixed The downslope time depends on the welding current Welding current downslope time *…
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Setup functions Start current level in use Start current level Start current level not in use During downslope the current can be ”frozen” onto a certain level, using the start switch Current ”freezing” ”Freeze” function is OFF Torch auxiliary switches are used to select TIG -torch auxiliary switches (RTC memory channels 20) *… -
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Setup functions Factory setting 20 A Contact ignition current * 3…2 Adjustment range 3…230 A Factory setting 1,0 s. Adjustment range 0,2…2,0 s. Spark ignition duration * …2. Factory setting 10 % of the welding current Downslope cutoff level * 5…4 Adjustment range 5…40 % of the welding current… -
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Setup functions Factory setting 0,0…15,0 s. Spot welding spot-time * 0…150 s. Factory setting MMA dynamics ** Adjustment range -9 = soft arc, 9 = rough arc 9…0 …9 Factory setting Adjustment range -9 = minimum overrun, 9 = MMA ignition pulse ** 9…0 maximum overrun …9… -
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Setup functions Factory setting 0,0 s. Pregas time minimum * Adjustment range 0,0…2,0 s. …2. Factory setting 1,0 s. Postgas time minimum * 0…1 Adjustment range 0…10 s. Factory setting -80 % Adjustment range -80…-10 % AC balance minimum * 80…… -
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Setup functions Factory setting 60 Hz AC frequency ** 50…250 Adjustment range 50…250 Hz Square wave AC waveform ** Sinus wave Factory setting 5 A Half cycle AC 5…20 Adjustment range 5…20 A Factory setting -25 % AC balance ** -50…10 Adjustment range -50…10 % Factory setting 100 %… -
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Setup functions Factory setting 50 % MIX TIG AC pulse ratio ** 10… Adjustment range 10…90 % Factory setting 100 % MIX TIG DC level ** 50… Adjustment range 50…150 % Factory setting 10 ms. Spotwelding time * 1…2 Adjustment range 1…200 ms. * Setting is always on ** Adjustable also by the Quick Setup… -
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Construction L001 Z004 Z002 A003 T002 Z001 (behind the isolator) T001 Z003 A004 A001 A002… -
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Main circuit diagram… -
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Operation principle Functions and components: Primary- and secondary inverter control This is the block diagram of an AC TIG -power source with active power factor correction. A power source based on this principle can be loaded in TIG -process with 230 A current by a duty cycle of 40 % (1~ 230 Vac / 16 A slow fuse). -
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Main circuit card Z001 Functions and components: Main circuit card Z001 includes following operational blocks: — Energy reserve — Power stage (full bridge) — Damping circuits — Gate buffers — Electrolyte capacitors C2, C3, C4 and C5 (470 F/450V) provide the energy storage — Power stage is a traditional full bridge, where the power switches are parallel connected discrete IGBTs (30A/600V). -
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Main circuit card Z001 Connectors: X8 Z004 X4 A001… -
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PFC card Z004 Functions and connectors: The PFC -card Z004 includes these operational blocks: — EMI -filter — Net connecting transient damping — Primary rectifier — PFC -power stage — PFC -power stage control — Net overvoltage watch — Auxiliary voltages developing — EMI -filter reduces the electromagnetic disturbances conducting to the net (EN50199). -
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PFC card Z004 Components: EMI –choke L002 Main switch S001 IGBT -transistor insulated from the heat Varistor R002 sink!!! EMI -filter Primary rectifier V1 X5 A001 X11 Z002 Diodes V2 and V3 Intermediate circuit X2 and X4: control card A002 charging resistor and relay power supply, 230 Vac… -
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Secondary rectifier Z002 Functions and main components Secondary diode card Z002 includes the following operational blocks: — Full wave rectifying for secondary — AC –welding auxiliary pulse rectifying — Damping circuits — Machine size code — Voltages of the main transformer’s secondary are rectified by a full wave rectifier, which consists of parallel connected diodes (60A/600V). -
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Secondary rectifier Z002 Connectors… -
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Secondary inverter Z003 Functions and main components The secondary inverter card Z003 includes these following operational blocks: — Power supply for control circuits — Gate control circuits — Under voltage watches — Secondary overvoltage protection — Secondary inverter s power stage Negative side IGBTs insulated from heat sink !!! Positive side IGBTs… -
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Secondary inverter Z003 Connectors X2 (A001) -
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A001 Control card Functions and connectors The control card A001 includes these following Secondary voltage watch, active operational blocks: Primary inverter PWM -control — Micro controller (Renesas M30262) — PWM -control DC+ mode — Shunt amplifier DC- mode — Supply overvoltage watch — Under voltage watch AC- auxiliary pulse, DC+ — Over temperature watch… -
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A002 Auxiliary power card Functions and connectors Auxiliary power supply card A002 includes the following operational blocks : — + 5 V (continuous) — + 24 V and + 15 V from main transformer T001 s auxiliary coils (Flyback chopper) — About + 20 V start power for the primary inverter’s gate buffers — Cooling unit ~ 230 V power supply + 15 V (lighted when power stage is on) -
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A003 Spark card Functions and connectors HF spark card A003 includes these following operational blocks: Voltage multiplier Spark on/off -control Spark voltage control Spark voltage adjustment… -
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A004 Interface card Functions and connectors Filter card A004 includes following operational blocks: Remote/foot control interface TIG –torch interface Panel interface Filtering of control lines… -
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It absolutely important because possible short circuit (e.g. improperly installed mica insulator) may damage the machine heavily. To execute following low voltage tests, Kemppi Multipower (and wire set) and digital multimeter is required. Be very careful and follow the instructions set by step to make everything in right order. Otherwise you may damage the machine or the testing equipment. -
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Measurements Secondary Z003 X6 heat sink Copper rail Z003 X9 22VAC Z003 X7 Jumper X12 Negative dix A002 X1 A002 X2 and X4 24 VDC 230 VAC Z004 X4 24 VDC Z004 ”heat sink” DC-link positive Z004 X15 DC-link negative… -
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• GND to the connector X15. Switch on the Kemppi Multipower and connect the 230VAC plug to the main supply voltage. ERR 3 should appear, if not machine cannot recognize the over/under voltage state. Connect jumper to the control card A001 jumper block X12 to mask off the Over/under voltage detection. -
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GND to the connector X15. Turn main switch to the OFF position. Switch on the Kemppi Multipower and connect the 230VAC test wire plug to the main supply voltage. Set machine to the TIG mode. Switch on the main switch (22VAC goes to the machine primary) •… -
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Test 3: Secondary over voltage watch (control card, secondary inverter card) Connect Kemppi multipower DC outputs (50 VDC, 24 VDC and 24 VDC) in the series. Outputs must be protected by PTC-resistors (included to the cable set). See picture below. -
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Installation of semiconductors Z001 Main circuit card Voltage of the heat sink is approx.+ 400 V Negative side IGBTs are insulated from the heat sink by Mica/Aluminium oxide insulators. Insulators have to be replaced every time the main circuit card Z001 is separated from the heat sink !!! Heat transferring paste is applied as thin layers on both sides of the insulators. -
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Installation of semiconductors Z004 PFC card Voltage of the heat sink is approx. + 400 V IGBTs V4.. V7 are insulated from the heat sink by Mica/Aluminium oxide insulators. insulators must be replaced every time the PFC- card Z004 is separated from heat sink !!! Heat transferring paste is applied as thin layers on both sides of the insulators. -
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Installation of semiconductors Z002 Secondary rectifier Negative side diodes are insulated from the heat sink by mica insulators. Mica insulators have to be replaced always, when the secondary diode card Z002 is separated from heat sink !!! Heat transferring paste is applied as thin layers on both sides of the insulators. -
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Installation of semiconductors Z003 Secondary inverter Negative side IGBTs are insulated from the heat sink by mica insulators. Mica insulators have to be replaced every time the main circuit card Z003 is disconnected from heat sink !!! Heat transferring paste is applied as thin layers on both sides of the mica insulators. -
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- Table of contents
- BOOKMARKS
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Operating manual • English
Käyttöohje • Suomi
Bruksanvisning • Svenska
Bruksanvisning • Norsk
Brugsanvisning • Dansk
Gebrauchsanweisung • Deutsch
Gebruiksaanwijzing • Nederlands
Manuel d’utilisation • Français
Manual de instrucciones • Español
Instrukcja obsługi • Polski
Инструкции по эксплуатации • По-русски
操作手册 • 中文
Manual de utilização • Português
Manuale d’uso • Italiano
EN
FI
SV
NO
DA
DE
NL
FR
ES
PL
RU
ZH
MasterTig
MLS 2300 ACDC
PT
IT
Summary of Contents
(Ocr-Read Summary of Contents of some pages of the Kemppi MLS 2300 ACDC Document (Main Content), UPD: 08 August 2023)
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10, EN 2.10 SHIELD GAS NOTE! Handle gas bottle with care. There is a risk for injury if gas bottle or bottle valve is damaged! Use inert gases such as argon, helium or argon-helium mixture as shield gas for TIG welding. Make sure that the gas ow regulator is suitable for the gas type used. The ow rate is set according to the welding current, joint form and the size of the electrode. A suitable ow rate is normally 8 – 10 l/min. If the…
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13, EN ACS welding panel – basic functions 1. 4. 5. 6. 8. 9. 7. 11. 10. 3. 2. 12. 13. 14. 15. 16. 17. 1. Selection button and indicators for TIG welding and current type 2. Selection button and indicators for MMA welding and current type 3. Current and voltage display, display for other welding parameters 4. QUICK SETUP button for MMA and TIG adjustments (e.g. balance adjustment) 5. Selection of the torch switch function 2T/4T 6. HF/contact TIG (WATER FILL) button 7. Remote co…
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7, EN Front of machine 1. Function panel 2. Remote control connector 3. TIG torch control connector 4. Shield gas and current connector for TIG torch 5. (+) connector for electrode holder 6. (–) connector for earth cable Markings for (+/–) poles on the machine front are embossed. Rear of machine 1. Mains switch 2. Snap connector for gas 1. 3. 2. 1. Installing gas-cooled torch 2. Installing water-cooled torch 3. Torch 2.5 INSTALLATION OF THE PANEL 1. 2. 1. Fas…
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4, EN CONTENTS 1. PREFACE ……………………………………………………………………………………………………………….. 3 1.1 General ……………………………………………………………………………………………………………………… 3 1.2 Product introduction ……………………………………………………………………………………………… 3 2. INSTALLATION ..…
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9, Kemppi MLS 2300 ACDC EN Installation of cooling unit: Electrical connection for the cooling unit: 1. 3. 2. 1. 230 V 2. Control connector 3. Equipment earth NOTE! Only an authorised electrician is allowed to install electrical connection! 7 MasterTig MLS 2300 ACDC / © Kemppi Oy / 1112
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17, EN Minilog When torch switch is pressed gas ow starts. When you release the torch switch current goes through upslope to Hot Start or Soft Start -current depending on adjustments and by pressing shortly again to welding current. After another short press it goes to Minilog operation, and you can select from two current levels: the welding current and the Minilog current. You can move from one to the other by quickly pressing…
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23, EN 6. TECHNICAL DATA Power source Mastertig MLS™ 2300 ACDC Connection voltage 1~230 V –15%…+15% Rated power 40% ED TIG 230 A 5,7 kVA 60% ED TIG 200 A 4,8 kVA 100% ED TIG 170 A 3,9 kVA 40% ED MMA 180 A 6,0 kVA 60% ED MMA 150 A 4,8 kVA 100% ED MMA 120 A 3,7 kVA Connection cable H07RN-F 3G2.5 (3.3 m) Fuse (delayed) 15 A Welding current range TIG 3 A / 10,0 V…230 A / 19,2 V MMA 10 A / 20,5 V…180 A / 27,2 V Max welding volta…
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22, Kemppi MLS 2300 ACDC EN 5. ORDERING NUMBERS Power source Mastertig MLS™ 2300 ACDC 6162300 Panels ACS 6162805 ACX 6162804 Cabels Welding cable 16 mm² 5 m 6184103 Welding cable 25 mm² 5 m 6184201 Welding cable 25 mm² 10 m 6184202 Welding cable 35 mm² 5 m 6184301 Earth cable 16 mm² 5 m 6184113 Earth cable 25 mm² 5 m 6184211 Earth cable 25 mm² 10 m 6184212 Earth cable 35 mm² 5 m 6184311 Torches TTC 160 4 m 627016004 TTC 160 8 m 6270…
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11, Kemppi MLS 2300 ACDC EN 3. OPERATION NOTE! Welding in places presenting an immediate re or explosion hazard is forbidden! NOTE! Welding fumes may cause injury, take care of sucient ventilation during welding! 3.1 WELDING PROCESSES 3.1.1 MMA welding With Mastertig MLS™ ACDC power sources you can use all electrodes suitable for direct and alternating current welding between current limits of the power source. Both function panels (ACS, ACX) can be used for electrode welding wh…
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21, EN 4.2 TROUBLESHOOTING Power On light is not lit. There is no power in the machine. • Check mains fuses, replace blown fuses. • Check mains cable and plug, replace defect parts. The machine is not welding properly. There are plenty of spatters during welding. Weld joint is porous or power supply is insucient. • Check welding settings and adjust if needed. • Check gas ow and gas hose connection. • Check that …
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26, 1910032 1112 www.kemppi.com KEMPPI OY Hennalankatu 39 PL 13 FIN-15801 LAHTI FINLAND Tel +358 3 899 11 Telefax +358 3 899 428 [email protected] www.kemppi.com Kotimaan myynti: Tel +358 3 899 11 Telefax +358 3 734 8398 myynti.@kemppi.com KEMPPI SVERIGE AB Box 717 S-194 27 UPPLANDS VÄSBY SVERIGE Tel +46 8 590 783 00 Telefax +46 8 590 823 94 [email protected] KEMPPI NORGE A/S Postboks 2151, Postterminalen N-3103 TØNSBERG NORGE Tel +47 33 346000…
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5, EN 1. PREFACE 1.1 GENERAL Congratulations on your choice of the Kemppi MasterTig MLS ACDC welding system. Reliable and durable, Kemppi products are aordable to maintain, and they increase your work productivity. This user manual contains important information on the use, maintenance and safety of your Kemppi product. The technical specications of the device can be found at the end of the manual. Pleas…
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14, EN 1. Dynamics (“Arc” –9 … 0 … +9) You will see the numerical value corresponding to the MMA dynamics in the display. Factory setting for all electrode types is zero. You can change the value by turning the pulse potentiometer. If numerical value is adjusted negative (-1…-9) the arc is softened, and the amount of spatter decreases when welding at the upper end of the recommended current range of the electrode. On the positive side (1…9) the arc is rough. 2.…
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15, EN 3. MIX TIG (mixed current AC/DC-) With mixed current frequency and balance of alternating current are determined by adjustments made for AC-current. Adjust by choosing sections 4. – 5. if needed. The following QUICK SETUP parameters can be adjusted: 1. AC-time (AC 10 … 90 %, factory setting 50 %) 2. Cycle time (CYc 0.1 … 1.0 s, factory setting 0.6 s) 3. DC-current (DC(-) 50 … 150 %, factory setting 100 %) 4.…
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19, EN 3.5 SETUPFUNCTIONS SETUP-function Display *C = Common: applies to all memory channels Factory setting with a grey background Upslope current dependency (*C) A1 ON The upslope time is determined by the current. OFF The upslope time remains as set. Downslope current dependency (*C) A2 ON The downslope time is determined by the current (the user may set the slope gradient). OFF The downslope time remains as set. TIG Antifreeze (*C) A3 ON TIG Antifreeze on. OFF TIG Antifreeze o…
Contents
1.
PREFACE…………………………………………………………………………………………………………………
3
1.1
General……………………………………………………………………………………………………………………….
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1.2
Product introduction……………………………………………………………………………………………….
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2.
INSTALLATION…………………………………………………………………………………………………..
4
2.1
Removal from packaging………………………………………………………………………………………..
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2.2
Locating the machine………………………………………………………………………………………………
4
2.3
Serial number……………………………………………………………………………………………………………
4
2.4
Installation and main parts……………………………………………………………………………………..
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2.5
Installation of the panel…………………………………………………………………………………………..
5
2.6
Mains connection……………………………………………………………………………………………………..
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2.7
Distribution network……………………………………………………………………………………………….
6
2.8
Welding cable connections…………………………………………………………………………………….
6
2.9
Cooling unit to Mastercool 20………………………………………………………………………………..
6
2.10
Shield gas…………………………………………………………………………………………………………………..
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3.
OPERATION………………………………………………………………………………………………………….
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3.1
Welding processes……………………………………………………………………………………………………
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3.1.1
MMA welding…………………………………………………………………………………………………….
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3.1.2 TIG welding Alternating Current………………………………………………………………………….
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3.1.3 TIG Welding with Direct Current………………………………………………………………………….
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3.1.4
Synergetic Pulsed TIG welding…………………………………………………………………………..
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3.1.5
Long Pulsed TIG welding…………………………………………………………………………………..
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3.1.6
Spot welding function………………………………………………………………………………………
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3.1.7
MicroTack™ function…………………………………………………………………………………………
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3.1.8 TIG-welding with mixed AC-DC current (MIX)……………………………………………………..
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3.2
Operation functions……………………………………………………………………………………………….
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3.2.1
Power source……………………………………………………………………………………………………
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3.2.2
Function panels………………………………………………………………………………………………..
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3.2.3
Saving welding settings…………………………………………………………………………………….
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3.2.4 Adopting the saved settings……………………………………………………………………………..
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3.2.5 Remote control memory channels……………………………………………………………………..
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3.2.6
SETUP functions……………………………………………………………………………………………….
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3.2.7 Foot pedal control R11F…………………………………………………………………………………….
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3.3
Cooling unit operation Mastercool 20………………………………………………………………..
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3.4
Storage……………………………………………………………………………………………………………………..
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3.5
SETUP-functions……………………………………………………………………………………………………..
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3.6
Error codes……………………………………………………………………………………………………………….
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4.
maintenance………………………………………………………………………………………………..
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4.1
Regular maintenance…………………………………………………………………………………………….
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4.2
Troubleshooting……………………………………………………………………………………………………..
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4.3
Disposal of the machine………………………………………………………………………………………..
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5.
Ordering numbers………………………………………………………………………………….
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6.
TECHNICAL DATA…………………………………………………………………………………………..
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