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Kemppi Mastertig MLS 3003 ACDC Service Manual
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Kemppi Mastertig MLS 3003 ACDC Service Manual

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Service manual
Mastertig MLS 3003 ACDC
Version 1.2
1

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Summary of Contents for Kemppi Mastertig MLS 3003 ACDC

  • Page 1 Service manual Mastertig MLS 3003 ACDC Version 1.2...

  • Page 2: Technical Data

    Technical data 3 ~ 230 V - 10% … 460 V +10%, 50/60 Hz Mains Voltage Mains cable H07RN-F 4G2.5, length 5 m Fuse 20/ 16A delayed fuse Rated power 100% 300A 190A 250A 190A Minimum Current TIG 3A ( AC 5A ) / MMA 10A Open circuit Voltage 58 V Power Factor at nominal values...

  • 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 Error code Description Err 3 Overvoltage Err 4 Over heating Err 6 Internal fault, secondary voltage over the limit.

  • 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 % -50…10 Adjustment range -50…10 % AC balance ** Factory setting 100 % 100…500...
  • 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 L002 A003 Z002 Spark Fans transformer Shunt resistor Main transformer Z004 Difference between 3000 / 3003, resistor R96 missing in 3003 Z003 Main switch, VDRs, EMC-choke… P001 Z001 Under insulator A004 A001 A002 PVC insulator Water cooler connectors...

  • Page 12: Main Circuit Diagram

    Main circuit diagram...

  • Page 13: Main Circuit Card Z001

    Main circuit card Z001 Functions and components: Z001 primary inverter main functions - full bridge topology - switching frequency (50 … 25kHz) 25kHz - electrolytic dc-link capacitors - emc filtering - gate and current transformers...
  • Page 14 Secondary rectifier Z002 Functions and main components Z002 secondary rectifier main functions - rectifies two voltages +60Vdc and -60Vdc - heat sink act as a conductor for positive terminal - stabilizing voltages are made by diode - capacitor multiplier - stabilizing voltage are regulated +-300Vdc (X5, X6) - snubbers for diodes - minus side diodes are insulated from heat sink by mica insulator Grey diodes must be insulated...
  • Page 15 Secondary inverter Z003 Functions and main components Z003 secondary inverter main functions - acts as a four level switch matrix (DC+, DC-, Aux+, Aux-) (heat sink, X5, X7, X9) - heat sink act as a conductor for positive terminal - minus side IGBTs are insulated from heat sink by mica insulator - gate drive circuits - protection against gate drive under voltage - optical isolation between control card gate drives...
  • Page 16 Pre-inverter (PFC) card Z004 Functions and connectors: - rectifies input input ac-voltages - provides soft start feature - soft-start ptc-resistor - soft start relay - input over voltage, under voltage and phase missing detection - increases rectified input voltage to 725Vdc - topology boost with two parallel paths - switching frequency 25kHz - maximum igbt current 40A peak...

  • Page 17: A001 Control Card

    A001 Control card Functions and connectors A001 Control Card Main Functions - current control (primary X4, secondary X8) - spark control (X7) - secondary inverter control (X2) - pre- inverter (pfc) and charge relay control (X5) - panel interface (X1) MLS3000 = R96 on / MLS3003 R96 off - magnetic valve control (X9) - fan control (X9)
  • Page 18 A002 Auxiliary power card Functions and connectors A002 Auxiliary Power Supply Main Functions - output voltage 24Vdc - input voltage range (450 … 750)Vdc (X1, X3) - output power 100W continuous with forced cooling - switching frequency 100kHz - topology flyback - forced “hiccup”...
  • Page 19 A003 Spark card Functions and connectors A003 HF generator card Main Functions - supply voltage 180Vac (main transformer) (X8, X9) - three parallel power igbts - HF-transformers primary voltage about 500Vdc - max. spark repetition frequency 500Hz with forced cooling (start control, X7) R27 = HF voltage adjusting R27 = HF voltage adjusting...
  • Page 20 A004 Interface card Functions and connectors A004 interface card main functions - panel bus interface (X2) - link between control card A001 and outside world (X1) - service and programming interface (X3) - tig control interface with protection against spark and +-100Vdc (X6) - remote control interface with protection against spark and +- 100Vdc (X5)
  • Page 21 Measurements Z001, Main circuit card : - Power should be off ! - With these measurements you can find short circuits and partly open circuits that indicates fault in the machine. - Measure diodes in forward and reverse direction. Forward diode threshold voltage is ~0,4V, reverse direction infinite.
  • Page 22 Measurements Z004 Pre-inverter, rectifier: - Power should be off ! - With these measurements you can find short circuits and partly open circuits that indicates fault in the machine. - Measure diodes in forward and reverse direction. Forward diode threshold voltage is ~0,5V, reverse direction infinite.
  • Page 23 Measurements Z004 Pre-inverter, IGBT: - Power should be off ! - With these measurements you can find short circuits and partly open circuits that indicates fault in the machine. - Measure diodes in forward and reverse direction. Forward diode threshold voltage is ~0,4 V, reverse direction infinite.
  • Page 24 Measurements Z003 Secondary inverter - Power should be off - Measure diodes and IGBTs in forward and reverse direction. Forward diode threshold voltage is about 0,45V, reverse direction high. - C-A, C-E, B-C, D-B, ~0,45V diode threshold voltage B-E, 0,7V diode threshold voltage D-C, 0,85V diode threshold voltage A (in+, heat sink) D (aux-)
  • Page 25 Connect Kemppi Multipower and digital multimeter with current measuring function to X7-1 (24 VDC) and X7-2 (GND). Switch on Kemppi Multipower and watch current consumption and test the panel functionality. < 300mA is OK (normally 120mA/24V without cooling fans and magnetic valve) •...
  • Page 26 Connect MLS-Service power DC+ (= 560Vdc) to wire connector X6 (goes to A002) and DC- to Z004/X8 (X6=560V, X8=0V). Connect Kemppi Multipower with 98 Vdc (24+24+50 Vdc in series) between phases L2, L3. Switch on MLS- Service power and check the panel functionality.
  • Page 27 Connect Kemppi Multipower with 22 VAC with current limit 2,5 A between phases L2, L3 Connect Kemppi MLS- Service power DC+ = 560Vdc to wire connector X6 and DC- to Z004/X8 (X6=560V, X8=0V). Again in newer model, connect DC+ to X6 cable going to A002/X1.
  • Page 28 Measurements TESTING OF THE SECONDARY OVER VOLTAGE WATCH Connect MLS- Service power voltages (24+24+50)Vdc in series by using PTC-resistor. Set the machine to DC- TIG mode. Connect the test voltage to output DIX terminals of the machine. If machine shows "Err 6" then it is OK. Repeat the test with reversed polarity.
  • Page 29 Installation of semiconductors IGBT mounting onto the heat sink The installation surfaces must be clean, even very small particles (0,050mm) between the surfaces increase the gap between heat sink and module, causing module overheating and possibly destruction. Heat transfer paste is spread as an even layer about 0,1 mm thick, onto the modules base plate.
  • Page 30 Installation of semiconductors Secondary rectifier Z002 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 mica insulators.
  • Page 31 Installation of semiconductors Secondary inverter Z003 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 32 Notes...