Kemppi MasterTig MLS 3003 ACDC User manual

1
Service manual
Mastertig MLS 3003 ACDC
Version 1.2

2
Technical data
The device may be repaired only by a person legally authorized
perform electric work!
Measured values may differ by the type and model of multimeter used.
Maximum power can be achieved with 20 kVA generator for the power source.
Mains Voltage 3 ~ 230 V - 10% … 460 V +10%, 50/60 Hz
Mains cable H07RN-F 4G2.5, length 5 m
Fuse 20/ 16A delayed fuse
Rated power 40% 100%
TIG 300A TIG 190A
MMA 250A MMA 190A
Minimum Current TIG 3A ( AC 5A ) / MMA 10A
Open circuit Voltage 58 V
Power Factor at nominal values 0,95
Efficiency at nominal values 80-84 % (250A / 30V)
77-81 % (300A / 22V)
Open circuit power TIG < 13W
MMA 190W
Electrode sizes to be welded 1,5 - 5,0 mm
Size ( l x w x h ) 500 x 180 x 390 mm
Weight 25 kg

3
User interface
1.2.
3.
4.
5.
6.
1. Gas connector for TIG torch
2. Welding current connection (negative)
3. Operation panel
4. Remote controller connection
5. TIG -torch control connection
6. Welding current connection (positive)
7. Main switch
8. Gas connector
7
8.
Error code Description
Err 3 Overvoltage
Err 4 Over heating
Err 6 Internal fault, secondary voltage over the limit.
Err 8 Maximum overheat time, machine doesn’t cool down fast enough. Only machine
shutdown and restart removes error.
Err 61 Water connection, water cooled gun connected without cooler.
COO Ler Cooler error:
- Cooling liquid over- / under pressure state
- Overheated alarm
BuS Err Communication between panel and power source isn’t possible
Err rSt System error, machine makes reset itself.

4
Setup functions
Welding current upslope time * A1
ON The upslope time depends on the welding
current
OFF The upslope time is fixed
Welding current downslope time * A2
ON The downslope time depends on the welding
current
OFF The downslope time is fixed
TIG Antifreeze * A3
ON TIG Antirfeeze is ON
OFF TIG Antifreeze is OFF
MMA Antifreeze * A4
ON MMA antifreeze is ON
OFF MMA antifreeze is OFF
VRD ***
(MMA open circuit voltage) A7
ON VRD-function: MMA open circuit voltage < 35
Vdc
OFF Normal open circuit voltage is 50 Vdc
2T-function´s downslope cutoff A8
ON On 2T-function the downslope is cut off by a
quick press on the start switch
OFF Quick press on the start switch has no function
Tacking automatics A9
ON Tacking automatics is ON; no downslope, if the
weld is shorter than 3 s
OFF Tacking automatics is OFF
Current upslope speed A10
ON If upslope time is 0,0 s, it goes to 0,2 s from the
halfway of currents > 100 A.
OFF Maximum current upslope speed
Method selection by remote
controller * A12
ON Method selection; TIG: minimum end of the
range of the remote controller, MMA: the
maximum end of the remote controller range
OFF The remote controller works as a normal current
adjustment
Entering the advanced setup press and hold the setup and Return buttons at the same
time. Changing the level press Setup button shortly
* Setting is always on ** Adjustable also by the Quick Setup *** Requires VRD card

5
Setup functions
Start current level A13
ON Start current level in use
OFF Start current level not in use
Current ”freezing” A14
ON During downslope the current can be ”frozen”
onto a certain level, using the start switch
OFF ”Freeze” function is OFF
TIG -torch auxiliary switches (RTC
20) * A15
ON Torch auxiliary switches are used to select
memory channels
OFF Torch auxiliary switches adjust welding current
TIG -torch auxiliary switches (RTC
20) activation * A16
ON Auxiliary switches are always active
OFF Auxiliary switches are active only when torch
control is selected
Cooling unit flow control * A17 ON Flow control is active
OFF Flow control is not active
Cooling unit control * A19
ON Controlled run
OFF Continous run
Coolant temperature watch * A20
ON Temperature watch is active
OFF Temperature watch is not active
Remote controller automatic
detection * A21
ON Automatic detection is ON
OFF Automatic detection is OFF
End current level A22
ON 4T-LOG: End current level is in use
OFF MINILOG: End current level is not in use
Tungsten electrode type *** A23 NOR Normal = Gray tungsten
GRN GRN = Green tungsten
* Setting is always on ** Adjustable also by the Quick Setup ***Depends on panel software version

6
Setup functions
Contact ignition current * B1
20 Factory setting 20 A
3…2
30
Adjustment range 3…230 A
Spark ignition duration * B2
1.0 Factory setting 1,0 s.
0.2
…2.
0
Adjustment range 0,2…2,0 s.
Downslope cutoff level * B3
10 Factory setting 10 % of the welding current
5…4
0
Adjustment range 5…40 % of the welding
current
Factory settings recall * B5
OFF Factory setting
PAN Recalls factory settings to the panel, but keeps
memory channels
ALL Recalls factory settings and empties the memory
channels
Downslope interruption –upslope
angle * B6
1 Upslope speed maximum
2 According to the upslope setting
3 According to the downslope
Non-linear downslope
(Current drop in the beginning of
downslope)
B7
OFF Factory setting
0…5
0
Adjustment range 0…50 % of welding current
Torch switch long press * B8
0.4 Factory setting 0,4 s.
0.3
…1.
0
Adjustment range 0,3…1,0 s.
Cooling unit post running time * B9 OFF Factory setting 4 min.
ON Post-running time 30 s.
* Setting is always on ** Adjustable also by the Quick Setup

7
Setup functions
Spot welding spot-time * B10
OFF Factory setting 0,0…15,0 s.
ON 0…150 s.
MMA dynamics ** B11
0 Factory setting
-
9…0
…9
Adjustment range -9 = soft arc, 9 = rough arc
MMA ignition pulse ** B12
0 Factory setting
-
9…0
…9
Adjustment range -9 = minimum overrun, 9 =
maximum overrun
Start current level * B13
10 Factory setting 10 % of the welding current
OFF Minimum current
5…4
0
Adjustment range 5…40 % of the welding
current
Display recovery time B14
5.0 Factory setting 5,0 s.
1.0
…20
,0
Adjustment range 1,0…20,0 s.
2T Hot Start duration ** B15
1.0 Factory setting 1,0 s.
0.1
…5.
0
Adjustment range 0,1…5,0 s.
* Setting is always on ** Adjustable also by the Quick Setup

8
Setup functions
Pregas time minimum * C1
0.0 Factory setting 0,0 s.
0.0
…2.
0
Adjustment range 0,0…2,0 s.
Postgas time minimum * C7
1.0 Factory setting 1,0 s.
0…1
0
Adjustment range 0…10 s.
AC balance minimum * C16
-80 Factory setting -80 %
-
80…
-10
Adjustment range -80…-10 %
Pregas time maximum * D1
1 Factory setting 1 s.
0…1
0
Adjustment range 0…10 s.
Postgas time maximum * D7
30 Factory setting 30 s.
15…
150
Adjustment range 15…150 s.
AC balance maximum * D16
10 Factory setting 10 %
0…2
0
Adjustment range 0…120 %
* Setting is always on ** Adjustable also by the Quick Setup

9
Setup functions
AC frequency ** E1
60 Factory setting 60 Hz
50…250 Adjustment range 50…250 Hz
AC waveform ** E2
Sqr Square wave
Sin Sinus wave
Half cycle AC E3
5 Factory setting 5 A
5…20 Adjustment range 5…20 A
AC balance ** E4
-25 Factory setting -25 %
-50…10 Adjustment range -50…10 %
Negative ignition current * E5
100 Factory setting 100 %
100…500 Adjustment range 100…500 % (Limited by
the max. of the power source)
Positive ignition current * E6
50 Factory setting 50 %
30…150 Adjustment range 30…150 % (Limited by the
max. of the power source)
Positive ignition sequence time * E7
10 Factory setting 10 = 0,01 s
0…20 Adjustment range 0…20 = 0,0…0,02 s
Ignition cycle total time */*** E8
0.20 Setting 0,20 s.
0.01…1,0 Adjustment range 0,01…1,0 s.
MIX TIG cycle time ** E9
0.6 Factory setting
0.1…1,0 Adjustment range 0,1…1,0 s.
* Setting is always on ** Adjustable also by the Quick Setup *** Note panel software version

10
Setup functions
MIX TIG AC pulse ratio ** E10
50 Factory setting 50 %
10…
90
Adjustment range 10…90 %
MIX TIG DC level ** E11
100 Factory setting 100 %
50…
150
Adjustment range 50…150 %
Spotwelding time * E12
10 Factory setting 10 ms.
1…2
00
Adjustment range 1…200 ms.
* Setting is always on ** Adjustable also by the Quick Setup

11
Construction
A003
Z004
Fans
Z002
Main transformer
Spark
transformer
Shunt resistor
Z003
PVC insulator
Main switch, VDRs,
EMC-choke…
Water cooler
connectors
A002
A001
A004
Z001
Under insulator
P001
L002
Difference between 3000 / 3003, resistor R96 missing in 3003

12
Main circuit diagram

13
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

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

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
Grey igbts must be insulated

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
- output power 10kW with 230Vac supply
Factory settings
for jumpers:
- X17 (1-4) = off
- X17 (2-5) = off
- X17 (3-6) = off
X17 (1-4)
no faults
X17 (2-5)
no freq. sweep
X17 (3-6)
pfc on
H1 reference
no visual meaning

17
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)
- magnetic valve control (X9)
- fan control (X9)
- interface to water cooling unit (X10)
- secondary over voltage fault (X3, X2-6)
- over temperature fault (X6, X11, X18)
- gate voltage fault
- 15V and 5V generation
- location of software
X16 jumper on = “mains switch always on”
X14 jumper on = “no over or under voltage error”
R108 = “switching frequency adjust”
X20 jumper on = “fixed frequency 25kHz”
X19 jumper on = “no frequency sweep”
Factory settings
- X16 = off
- X14 = off
- X20 = off
- X19 = on
- R108 = 25kHz
MLS3000 = R96 on / MLS3003 R96 off
H4 = gate drive on
H2 = output over
voltage
H1 = pre inverter (pfc) on
H8 = secondary dc-
H9 = secondary aid+
H6 = secondary dc+
H3 = +15Vdc
H7 = +24Vdc
H10 = HF (spark)
H11 = secondary aid-
H5 = +5Vdc
X4X5
X11X9 X17
X18
X1
X2
X8
X3
X6
X7
X10
X12

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” mode in overload (X17 off)
- over voltage switch off about 830Vdc
- low voltage wake-up 200Vdc
- supply 24Vdc also to water cooler unit
- floating secondary inverter gate drive voltages 35Vdc
- supply also auxiliary power to pre-inverter and
primary diode card 35Vdc (X2)
primary
secondary
X17 = no forced “hiccup” mode
H5 = gate voltage aid+
H4 = gate voltage dc+
H1 = 24Vdc
H2 = gate voltage aid-
H3 = gate voltage dc-
Factory setting
X17 = off

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
range (8.5 .. 13)kV
R27 = HF voltage adjusting
range (8.5 .. 13)kV

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)