Service Manual Mastertig MLS 2300 ACDC: Downloaded From Manuals Search Engine
Service Manual Mastertig MLS 2300 ACDC: Downloaded From Manuals Search Engine
Service Manual Mastertig MLS 2300 ACDC: Downloaded From Manuals Search Engine
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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)
60% ED 150 A / 26,0 V (4,8 kVA)
100% ED 120 A / 24,8 V (3,7 kVA)
Supply cable / fuse 2,5 mm² S - 3,3 m / 16 A slow
Adjustment range
TIG 3 A (AC 5 A) / 10,0 V…230 A / 19,2 V
MMA 10 A / 20,4 V…180 A / 27,2 V
Maximum welding voltage 32 V / 180 A
OCV 50 V
Efficiency 0,8
Power factor 0,99
Open circuit power
TIG 6W
MMA 180 W
Degree of protection IP 23C
Measures
Length 500 mm
Width 180 mm
Height 260 mm
Weight 15 kg
8 kVA generator can provide maximum output power for the power source however
recommended generator size is 10 kVA
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User interface
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8
3
5
1
2 6
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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
ON The upslope time depends on the welding
Welding current upslope time * A1 current
OFF The upslope time is fixed
ON The downslope time depends on the welding
Welding current downslope time * A2 current
OFF The downslope time is fixed
ON TIG Antirfeeze is ON
TIG Antifreeze * A3
OFF TIG Antifreeze is OFF
ON MMA antifreeze is ON
MMA Antifreeze * A4
OFF MMA antifreeze is OFF
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Setup functions
ON Automatic detection is ON
Remote controller automatic
A21
detection * OFF Automatic detection is OFF
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Setup functions
20 Factory setting 20 A
Contact ignition current * B1
3…2 Adjustment range 3…230 A
30
1.0 Factory setting 1,0 s.
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Setup functions
0 Factory setting
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Setup functions
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Setup functions
60 Factory setting 60 Hz
AC frequency ** E1
50…250 Adjustment range 50…250 Hz
Sqr Square wave
AC waveform ** E2
Sin Sinus wave
5 Factory setting 5 A
Half cycle AC E3
5…20 Adjustment range 5…20 A
-25 Factory setting -25 %
AC balance ** E4
-50…10 Adjustment range -50…10 %
100 Factory setting 100 %
Negative ignition current * E5 100…500 Adjustment range 100…500 % (Limited by
the max. of the power source)
50 Factory setting 50 %
Positive ignition current * E6 30…150 Adjustment range 30…150 % (Limited by
the max. of the power source)
10 Factory setting 10 = 0,01 s
Positive ignition sequence time * E7
0…20 Adjustment range 0…20 = 0,0…0,02 s
0.20 Factory setting 0,2 s (up to 0A8) / 0,01 s
Ignition cycle total time * E8 (since 0A9).
0.01…1,0 Adjustment range 0,01…1,0 s.
0.6 Factory setting
MIX TIG cycle time ** E9
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
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Setup functions
50 Factory setting 50 %
MIX TIG AC pulse ratio ** E10
10… Adjustment range 10…90 %
90
100 Factory setting 100 %
MIX TIG DC level ** E11 50… Adjustment range 50…150 %
150
10 Factory setting 10 ms.
Spotwelding time * E12 1…2 Adjustment range 1…200 ms.
00
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Construction
L001
Z004
Z002
A003
T002
Z003
A004
A001
A002
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Main circuit diagram
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Operation principle
Functions and components:
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).
Error code Description
Err 3 Over/Undervoltage
Err 4 Overheating
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 cooled gun connected but no water cooler in the system.
Cooler 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.
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Main circuit card Z001
Functions and components:
- Energy reserve
- Power stage (full bridge)
- Damping circuits
- Gate buffers
- Electrolyte capacitors C2, C3, C4 and C5 (470µF/450V) provide the energy storage
- Power stage is a traditional full bridge, where the power switches are parallel connected discrete
IGBTs (30A/600V).
- The current transformer T1 measures the primary current
Note ! IGBTs V12 – V14 and V9 – V11 are insulated from the heat sink!
- Primary inverter's operating frequency is constant, being approx. 65 kHz (cycle time is about 15,3 µs)
throughout the whole power range. Power is controlled by changing the IGBT’s conductivity timings.
Energy reserve
Current transformer
Pulse transformer
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Main circuit card Z001
Connectors:
X8 Z004
X2 X1
X8 X7
X6
X5
X4
X3
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).
- The net connecting transient is damped by the PTC-resistor R23 and relay K1 together. The rectifier
unit V1 rectifies the net voltage to DC, which can fluctuate between + 260…380 V. Power
supply to the power supply card A002 via connectors X13 and X14.
- PFC’s power stage (boost converter) increases the full-wave rectified net voltage up to +400 V DC and
forces the net current into sinus form.
- Note. IGBT -transistors V4…V7 are insulated from the heat sink! Diodes V2 and V3 are not insulated, so
diode cathodes and heat sink share the same potential approx. + 400 V!
X2 X3 X5 X7
X1
X8
X14 X15
X13
X10
X9 X6
X12
X11
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PFC card Z004
Components:
IGBT -transistor
Varistor R002 insulated from the heat
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
- Voltages of the main transformer's secondary are rectified by a full wave rectifier, which consists
of parallel connected diodes (60A/600V). Note ! Diodes V11 – V15 and V16 – V20 are insulated
from the heat sink !!!
- Damping circuits (RC) reduce the voltage stress of secondary diodes. The machine size is coded
by resistor R1 s value.
- AC –welding auxiliary pulses are developed from the voltages of the auxiliary coils of the main
transformer T001. AC –welding auxiliary pulses stabilize the AC -arc by increasing secondary
voltage up to +/- 350 V (max. about 500 µs) at the beginning of the half cycle. Chokes L1 and L2
limit the current to a few amps.
AC -welding
auxiliary pulse chokes
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Secondary rectifier Z002
Connectors
X8 X4 X3
X7
X11 X9
X10
X1 X2
X6 X5
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Secondary inverter Z003
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Secondary inverter Z003
Connectors
X6
X13
X9
X18 X4
X17
X2
X16
X8
X12 X3
X19
X11
X1
X15 X7
X2 (A001)
X14
X5
X10
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A001 Control card
Functions and connectors
The control card A001 includes these following
operational blocks: H1 Secondary voltage watch, active
X4 R96
H1 H2
X17
X6
X10
X5
X11 X9 H6 X8 X7
H7 H3 X3
X1
H4 H5 X2
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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
X7
H3
X9
X8 X1
X4
X7 (A001) X2
X6
X5
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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
X1
X3
R47
Spark voltage adjustment
X3 X2
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A004 Interface card
Functions and connectors
Filter card A004 includes following operational blocks:
X3 X2
X1
X9
X4
X5
X6
X7
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Measurements
Tests in the following pages (three tests) have to be done after replacing any primary or secondary
units or cards. 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.
Remember to measure DC-link is not charged while making any connections. In the case it is in high
voltage state you may injure yourself or damage the Kemppi multipower.
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Measurements
Secondary
Z003 X6 heat sink
Copper rail
Z003 X9
22VAC
Z003 X7
Z004 X4
24 VDC
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Measurements
Next test
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Measurements
Test 2: PFC card
1. Disconnect cooling fans.
2. Connect jumper to the control card A001 jumper block X12. If not connected -> ERR 3
3. Auxiliary power supply card A002:
• Disconnect wires from connectors X2 and X4 and connect 230 VAC connector to the X2
and X4 (Do not connect it to the main supply voltage). Use the wire delivered with the
multipower wire set.
• Disconnect connector X1 and connect 24 VDC from Kemppi Multipower to the card
connector X1.
4. PFC card Z004:
• Disconnect connector X4 and connect 24 VDC from Kemppi Multipower to the PFC card
connector X4.
5. Connect Multipower 22VAC to the main supply cable.
• Current limit must be set to 2,5A
6. Connect test wires to DC-link and DMM. Connections can be found on the Z004 card:
• DC-link positive in the heat sink via screw.
• GND to the connector X15.
7. Turn main switch to the OFF position.
8. Switch on the Kemppi Multipower and connect the 230VAC test wire plug to the main supply voltage.
9. Set machine to the TIG mode.
10. Switch on the main switch (22VAC goes to the machine primary)
• DC-link voltage should raise up to approx. 400 VDC.
• NOTE!! 430 VDC is maximum value. If the voltage rises higher switch off the main switch ->
PFC-circuit is not working correctly.
• If voltage is OK -> PFC is working correctly.
11. Switch off the machine main switch.
12. Switch the machine to MMA mode to discharge the DC-link.
13. Switch OFF the Kemppi Multipower and disconnect 230VAC main supply voltage plug.
14. Disconnect the testing wires and connect back A002 and Z004 wires.
15. Disconnect jumper from the control card A001 jumper block X12.
16. Connect cooling fans
Next test
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Measurements
Test 3: Secondary over voltage watch (control card, secondary
inverter card)
1. 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.
2. Switch ON the Kemppi Multipower.
3. Switch ON the machine.
4. Set machine to the TIG-mode.
5. Touch to the machine terminals with tester wires.
6. Machine will show Err 6 on the display, if secondary voltage watch is working correctly.
7. Test secondary voltage watch with reversed polarity !
8. Disconnect the A001 X3 connector and switch the machine to MMA, error 6 should appear.
9. Connect A001 X3 connector to control card.
Kemppi Multipower
24 VDC 24 VDC 50 VDC
PTC PTC
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Installation of semiconductors
Z001 Main circuit card
Note!
Aluminium oxide insulators are more
reliable in the primary and should be
used always if any primary repair work
is done. They are thicker than micas so
heat sink must be replaced.
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Installation of semiconductors
Z004 PFC card
Note!
Aluminium oxide insulators are more
reliable in the primary and should be
used always if any primary repair work
is done. They are thicker than micas so
heat sink must be replaced.
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Installation of semiconductors
Z002 Secondary rectifier
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Installation of semiconductors
Z003 Secondary inverter
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Notes
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