Kemppi MLS 2300 ACDC Service Manual
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Kemppi MLS 2300 ACDC Service Manual

Pulse tig welder
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Service manual

Mastertig MLS 2300 ACDC
Version 1.3.1
1

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Summary of Contents for Kemppi MLS 2300 ACDC

  • Page 1: Service Manual

    Service manual Mastertig MLS 2300 ACDC Version 1.3.1...

  • 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)

  • 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...

  • 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 *...
  • Page 5 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) *...
  • Page 6 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...
  • Page 7 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...
  • Page 8 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…...
  • Page 9 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 %...
  • Page 10 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...
  • Page 11 Construction L001 Z004 Z002 A003 T002 Z001 (behind the isolator) T001 Z003 A004 A001 A002...
  • Page 12 Main circuit diagram...
  • Page 13 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).
  • Page 14 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).
  • Page 15 Main circuit card Z001 Connectors: X8 Z004 X4 A001...
  • Page 16 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).
  • Page 17 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...
  • Page 18 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).
  • Page 19 Secondary rectifier Z002 Connectors...
  • Page 20 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...
  • Page 21 Secondary inverter Z003 Connectors X2 (A001)
  • Page 22 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...
  • Page 23 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)
  • Page 24 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...
  • Page 25 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...
  • Page 26 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.
  • Page 27 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...
  • Page 28 • 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.
  • Page 29 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) •...
  • Page 30 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.
  • Page 31 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.
  • Page 32 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.
  • Page 33 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.
  • Page 34 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.
  • Page 35 Notes...

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