MLS 3000, 3003 ACDC
MasterTig
MLS 3000 ACDC VRD
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OPERATING MANUAL
English
MasterTig MLS 3000, 3003 ACDC / © Kemppi Oy / 1112
CONTENTS
EN
MasterTig MLS 3000, 3003 ACDC / © Kemppi Oy / 1112
1. PREFACE
1.1 General
1.2 Introduction
................................................................................................................................ 3
....................................................................................................................................... 3
............................................................................................................................. 3
2. INSTALLATION ................................................................................................................. 4
2.1 Removal from packaging .................................................................................................... 4
2.2 Locating the machine ........................................................................................................... 4
2.3 Serial number ........................................................................................................................... 4
2.4 Installation and main parts ................................................................................................. 4
2.5 Installation of the panel ....................................................................................................... 6
2.6 Mains connection ................................................................................................................... 6
2.7 Distribution network ............................................................................................................. 6
2.8 Welding cable connections ................................................................................................ 7
2.9 Cooling unit to Mastercool 30 ........................................................................................... 7
2.10 Shield gas .................................................................................................................................. 9
3. OPERATION ......................................................................................................................10
3.1 Welding processes
3.1.1 MMA welding .................................................................................................................10
3.1.2 TIG welding Alternating Current ..................................................................................10
3.1.3 TIG Welding with Direct Current ...................................................................................10
3.1.4 Synergetic Pulsed TIG welding .....................................................................................11
3.1.5 Long Pulsed TIG welding ...............................................................................................11
3.1.6 Spot welding function ...................................................................................................11
3.1.7 MicroTack™ function ......................................................................................................11
3.1.8 TIG-welding with mixed AC-DC current (MIX) .............................................................11
3.2 Operation functions ............................................................................................................11
3.2.1 Power source ..................................................................................................................11
3.2.2 Function panels .............................................................................................................11
3.2.3 Saving welding settings ................................................................................................16
3.2.4 Adopting the saved settings .........................................................................................17
3.2.5 Remote control memory channels ...............................................................................17
3.2.6 SETUP functions .............................................................................................................17
3.2.7 Foot pedal control R11F ................................................................................................17
3.3 Cooling unit operation Mastercool 30
3.4 Storage
.....................................................................................................................................17
3.5 SETUP-functions
3.6 Error codes ..............................................................................................................................19
...............................................................................................................10
.........................................................................17
...................................................................................................................18
4. MAINTENANCE ..............................................................................................................19
4.1 Regular maintenance ..........................................................................................................19
4.2 Troubleshooting ...................................................................................................................20
4.3 Disposal of the machine ....................................................................................................20
5. ORDERING NUMBERS .............................................................................................20
6. TECHNICAL DATA ........................................................................................................22
2
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. Please read the manual carefully before using the equipment for the rst time.
For your safety and that of your working environment, pay particular attention to the safety
instructions in the manual.
For more information on Kemppi products, contact Kemppi Oy, consult an authorised Kemppi
dealer, or visit the Kemppi Web site at www.kemppi.com.
The specications presented in this manual are subject to change without prior notice.
Important notes
Items in the manual that require particular attention in order to minimise damage and
personal harm are indicated with the ’NOTE!’ notation. Read these sections carefully and follow
their instructions.
Disclaimer
While every eort has been made to ensure that the information contained in this guide
is accurate and complete, no liability can be accepted for any errors or omissions. Kemppi
reserves the right to change the specication of the product described at any time without
prior notice. Do not copy, record, reproduce or transmit the contents of this guide without
prior permission from Kemppi.
1.2 INTRODUCTION
Kemppi Mastertig MLS ACDC is a family of TIG welding machines designed for industrial use,
with characteristics especially suitable for welding materials like aluminium and stainless steel.
The equipment consists of power source, function panel and welding torch. The cooling unit
Mastercool 30 is used in water-cooled TIG welding. The welding torch can be either watercooled or gas-cooled.
Multipurpose power sources Mastertig MLS™ 3000 and 3003 ACDC of 300 A maximum current
is designed for demanding professional welding, suitable for electrode, TIG and pulsed TIG
welding with both direct and alternating current. The power source is controlled with IGBT
transistors with a frequency of approximately 30 kHz, and the operational functions with a
microprocessor.
Mastertig MLS 3000 ACDC is connected to a 400-V three-phase network. Mastertig MLS 3003
ACDC is a multi-voltage power source that operates steplessly in the three-phase range
230–460 V.
Mastertig MLS 3000 ACDC VRD is equipped with so called Voltage Reduction Device (VRD)
function to avoid danger of electric shock. VRD maintains open circuit voltage under 35 V.
MasterTig MLS 3000, 3003 ACDC / © Kemppi Oy / 1112
EN
3
2. INSTALLATION
2.1 REMOVAL FROM PACKAGING
The equipment is packed in durable packages designed especially for it. However, it is
necessary to check the equipment before using it to make sure that the equipment or any part
of it has not got damaged during transportation. Also check that the delivery corresponds to
your order and that you have received all necessary instructions for installing and operating
the equipment. The packaging material is recyclable.
2.2 LOCATING THE MACHINE
Place the machine on a horizontal, stable and clean ground. Protect the machine from rain
and direct sunshine. Check that there is enough space for cooling air circulation in front of and
behind the machine.
2.3 SERIAL NUMBER
Serial number of the machine is marked on the rating plate. The serial number is the only
proper means of identifying parts for a specic product. It is important to make correct
reference to the serial number of the product when making repairs or ordering spare parts.
2.4 INSTALLATION AND MAIN PARTS
MasterTig MLS 3000, 3003 ACDC / © Kemppi Oy / 1112
EN
1.
1.
2.
3.
4.
5.
6.
2.
4
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.
Installing gas-cooled torch
Rear of machine
1. Mains switch
2. Snap connector for gas
MasterTig MLS 3000, 3003 ACDC / © Kemppi Oy / 1112
Installing water-cooled torch
Connect the red water hose to the upper connector and blue one to the lower connector.
EN
5
2.5 INSTALLATION OF THE PANEL
1. Fasten the cable connectors of the function panel to the power source (2 pieces).
2. Place the bottom edge of the panel behind the securing clips on the machine. Remove the
xing pin from the top edge with, for example, a screwdriver. Then gently push the
upper part of the panel into place. Make sure that the cables do not get damaged,
MasterTig MLS 3000, 3003 ACDC / © Kemppi Oy / 1112
continue gently pushing the upper part of the panel until it clips into place. Finally, push
the xing pin back into its place.
EN
2.6 MAINS CONNECTION
NOTE! Only an authorised electrician is allowed to install mains cable and plug!
The machine is equipped with a ve-metre power cord. Only an authorised electrician is
allowed to install the plug. The fuse and cable sizes are given in the Technical data at the end
of this manual.
2.7 DISTRIBUTION NETWORK
All regular electrical devices without special circuits generate harmonic currents into
distribution network. High rates of harmonic current may cause losses and disturbance to
some equipment.
MasterTig MLS 3000 ACDC
WARNING: This equipment does not comply with IEC 61000-3-12. If it is connected to a public
low voltage system, it is the responsibility of the installer or user of the equipment to ensure,
by consultation with the distribution network operator if necessary, that the equipment may
be connected.
MasterTig MLS 3003 ACDC
This equipment complies with IEC 61000-3-12 provided that the short-circuit power Ssc
is greater than or equal to 1.2 MVA at the interface point between the user’s supply and
the public supply network. It is the responsibility of the installer or user of the equipment
to ensure, by consultation with the distribution network operator if necessary, that the
equipment is connected only to a supply with a short-circuit power Ssc greater than or equal
to 1.2 MVA.
6
2.8 WELDING CABLE CONNECTIONS
The welding cables must be made of at least 25 mm² copper cable.
2.8.1 Choosing welding polarity in MMA welding
You can select the polarity electronically from the control panel, i.e. you do not have to switch
the places of the (+) and (-) connectors.
NOTE! Connect always the negative connector to the work piece.
2.8.2 Earthing
If possible, always fasten the earth clamp of return current cable directly onto work piece.
1. Clean contact surface of earth clamp from paint and rust.
2. Fasten clamp properly, so that contact surface is as large as possible.
3. Check that clamp is fastened rmly.
2.9 COOLING UNIT TO MASTERCOOL 30
NOTE! Cooling liquid is injurious! Avoid also contact with skin or eyes. In case of injury, seek for
medical advice.
Cooling unit Mastercool 30 together with TIG torch Kemppi TTC-W range enables TIG welding
with water-cooled torch.
The cooling unit is installed beneath the power source with screws. Electrical connections are
on the bottom of power source. Fill the reservoir with a 20 – 40 % mixture of glycol and water,
or with any other suitable antifreeze. The capacity of the reservoir is 3 litres.
MasterTig MLS 3000, 3003 ACDC / © Kemppi Oy / 1112
Mastercool 30
EN
7
MasterTig MLS 3000, 3003 ACDC / © Kemppi Oy / 1112
Installation of cooling unit:
EN
Electrical connection for the cooling unit:
2.
1.
1. Control connector
2. Protective earth
NOTE! Only an authorised electrician is allowed to install electrical connection! See the mounting
instructions delivered with the cooling unit.
8
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 gas ow is not suitable the welded joint will be porous. Spark
ignition becomes more dicult if the gas ow is too high. Contact your local Kemppi dealer
for choosing gas and equipment.
A
C
Parts of gas ow regulator
A. Gas bottle valve
B. Pressure regulation screw
C. Connecting nut
D. Hose spindle
E. Jacket nut
F. Gas bottle pressure meter
G. Gas hose pressure meter
2.10.1 Installation of gas bottle
F
G
B
E
D
MasterTig MLS 3000, 3003 ACDC / © Kemppi Oy / 1112
EN
NOTE! Always fasten gas bottle properly in vertical position in a special holder on the wall or on a
carriage. Remember to close gas bottle valve after having nished welding.
The following installation instructions are valid for most gas ow regulator types:
1. Step aside and open the bottle valve (A) for a while to blow out possible impurities from the
bottle valve. Note! Watch out for the gas ow.
2. Turn the press regulation screw (B) of the regulator until no spring pressure can be felt.
3. Close needle valve if there is one in the regulator.
4. Install the regulator on bottle valve and tighten connecting nut (C) with a wrench.
5. Install hose spindle (D) and jacket nut (E) into gas hose and tighten with hose clamp.
6. Connect one end of the hose with the regulator and the other end with the power source.
Tighten the jacket nut.
7. Open bottle valve slowly. Gas bottle pressure meter (F) shows the bottle pressure.
NOTE! Do not use the whole contents of the bottle. The bottle should be lled when the bottle
pressure is 2 bar.
8. Open needle valve if there is one in the regulator.
9. Turn regulation screw (B) until hose pressure meter (G) shows the required ow (or pressure).
When regulating ow amount, the power source should be switched on and the gun
switch pressed simultaneously.
Close bottle valve after having nished welding. If the machine will be out of use for a long
time, unscrew the pressure regulation screw.
9
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 almost 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 when MMA welding is selected.
3.1.2 TIG welding Alternating Current
The Mastertig ACDC MLS™ power sources are specially designed for TIG welding aluminium
with alternating current (AC). We recommend using WC20 electrodes (grey) for AC welding.
The table is only given as a guide.
Welding current range AC Electrode Gas nozzle Gas flow rate
min. min. maks. WC20
MasterTig MLS 3000, 3003 ACDC / © Kemppi Oy / 1112
Argon
EN
A A A l/min
15 25 90 1.6 4 / 5 / 6 6.5 / 8.0 / 9.5 6...7
20 30 150 2.4 6 / 7 9.5 / 11.0 7...8
30 45 200 3.2 7 / 8 / 10 11.0 / 12.5 / 16 8...10
40 60 350 4.0 10 / 11 16 / 17.5 10...12
The table and the panel scale are based on the use of WC20 (grey).
ø mm number ø mm
3.1.3 TIG Welding with Direct Current
DC welding is typically used when welding dierent grades of steel. We recommend using
WC20 electrodes (grey) for DC welding.
A directive electrode selection table for DC welding.
Welding current range DC Electrode Gas nozzle Gas flow rate
WC20
A ø mm l/min
5...80 1.0 4/5 6.5 / 8.0 5...6
70...140 1.6 4 / 5 / 6 6.5 / 8.0 / 9.5 6...7
140...230 2.4 6 / 7 9.5 / 11.0 7...8
225...330 3.2 7 / 8 / 10
Argon
number ø mm
11.0 / 12.5 / 16 8...10
10
3.1.4 Synergetic Pulsed TIG welding
The ACX panel includes the synergetic TIG process, in which you only need to adjust the
welding current while other pulse parameters are programmed. Pulsing frequency is high,
which guarantees concentrated arc and increased welding speed.
3.1.5 Long Pulsed TIG welding
This method gives you the possibility to adjust all pulse parameters. Weld pool control is also
easier. Long pulsed TIG welding is included in the ACX panel.
3.1.6 Spot welding function
In spot welding function you can to adjust the duration of the welds in the range 0-10 s.
3.1.7 MicroTack™ function
MicroTack welding is an ecient way to connect thin materials together using low heat input,
which decreases distortions in base material.
3.1.8 TIG-welding with mixed AC-DC current (MIX)
Especially joining aluminium materials of dierent thicknesses can best be made out by using
mixed current. Adjust values with SETUP-function if needed.
3.2 OPERATION FUNCTIONS
3.2.1 Power source
NOTE! Always switch the machine on and o from main switch. Do not use the mains plug for
switching!
NOTE! Never watch the arc without a proper face shield designed for arc welding! Protect yourself
and the surroundings against welding arc and hot spatters!
3.2.2 Function panels
Before welding starts, welding settings suitable for the work piece are chosen with the
function panel.
The Kemppi Multi Logic System, MLS™, allows you to select the function panel based on the
purpose of use: the ACS panel for AC TIG welding with basic functions, or the ACX panel with
pulsed TIG, 4T-LOG or MINILOG control of welding current and memory channel functions.
The current display accuracy is 3 % ± 2 A, and the voltage display accuracy is 3 % ± 0.2 V.
Indicator lights
1.
MasterTig MLS 3000, 3003 ACDC / © Kemppi Oy / 1112
EN
2. 3.
1. Power On
2. Thermal overload of power source
3. Wrong mains voltage, over or under-voltage
11
ACS welding panel – basic functions
12. 13. 14. 15. 16.
EN
MasterTig MLS 3000, 3003 ACDC / © Kemppi Oy / 1112
1.
4.
9.
5.
8.
6.
2.
17.
3.
10.
11.
7.
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 control selection button (setting the limits for the adjustment range: LO/HI)
8. Welding parameter selection buttons (arrow buttons)
9. RETURN button / returns to welding current
10. GAS TEST button
11. Control knob for welding parameter adjustment
12. Pre-gas 0.0 - 10.0 s
13. Upslope 0.0 - 10.0 s
14. Hot Start current 100 – 150 % (100 %: not in use)
15. Welding current
16. Downslope 0.0 - 15.0 s
17. Post-gas 1.0 - 30.0 s
1. MMA
Select MMA welding by pressing the MMA selection button. The indicator light next to the
button will light up when MMA is selected. The current type indicator light indicates which
current is selected: AC, DC-, DC+. Change the current type by pressing the MMA button again,
and the indicator light will indicate the selected current.
Press the QUICK SETUP button if you wish to adjust the dynamics or ignition pulse to MMA
welding. Navigate with the arrow buttons and adjust with the control knob. Quit by pressing
again QUICK SETUP- or RETURN-button.
12
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 control
knob. 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. Ignition pulse (Hot –9 … 0 … +9)
You will see on the display the numerical value corresponding to the MMA ignition pulse.
You can adjust the value by turning the control knob. A positive value corresponds to a more
powerful pulse, with zero being the default setting.
2. TIG welding
Select TIG welding by pressing the TIG button. You can change the current type by
pressing the selection button again (AC, MIX, DC-, DC+). Selecting DC+ requires holding
down the button. According to selected current mode you can adjust parametres by
using QUICK SETUP -function. Quit from QUICK SETUP -function by pressing QUICK SETUP
-button. At the same time you can see recommended diameter for electrode.
AC TIG (alternating current TIG)
Intended for welding aluminium. You can adjust, for example, the balance and frequency
of the alternating current with the QUICK SETUP and arrow buttons. The following
welding parameters can be adjusted:
1. Balance (bAL -50 … 0 %, factory setting –25 %)
In AC welding the ratio of the positive and negative half waves is called the balance. It
determines the heat input proportions to the base material and to the electrode.
MasterTig MLS 3000, 3003 ACDC / © Kemppi Oy / 1112
Eect of the balance adjustment:
A positive balance value breaks up aluminium oxide more eectively but heats the
electrode more than the workpiece (the tip blunts).
A negative balance value increases heat generation and penetration in the base metal,
while decreasing oxide break-up.
If you wish to increase electrode temperature when welding with a blunt-headed
electrode, adjust the balance in the positive direction, and if you wish to decrease
electrode temperature when welding with a sharp electrode, adjust the balance
correspondingly in the negative direction.
At the factory setting, the electrode tip remains almost sharp.
A sharp electrode allows welding with a narrower arc, achieving a narrower weld and
deeper penetration than with a blunted electrode. Narrow welding is especially useful
when welding a llet weld.
Welding with a blunted electrode produces a wide arc, which also widens the area of
oxide break-up. Application areas include repair welding and casting.
2. Frequency (FrE 50 … 250 Hz, factory setting 60 Hz)
Raising the frequency will make the arc slightly more stable and narrow, but it will
increase the noise caused by arc.
3. Selection of AC waveform, sine or square wave (SinuS/SquArE)
The waveform aects the noise level and penetration of the arc. A sine waveform
generates a lower noise level, while a square wave has better penetration (factory setting).
4. Hot Start time for the 2T function (H2t 0.1 s…5.0 s, factory setting 1.0 s)
Pre-heating timer for the 2T switch function. The workpiece can be pre-heated (Hot Start)
with both AC and DC currents. The time set here remains in eect for DC TIG current types.
EN
13
MasterTig MLS 3000, 3003 ACDC / © Kemppi Oy / 1112
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. Balance (bAL -50 … 0 … +10 %, factory setting –25 %)
5. Frequency (FrE 50 … 250 Hz, factory setting 60 Hz)
6. Selection of AC waveform, sine or square wave (SinuS/SquArE)
7. Hot Start time for the 2T function (H2t 0.1 s…5.0 s, factory setting 1.0 s). Can be seen only on
the 2T function.
Factory setting is marked with a dot after the numeric value.
Growing DC-current increases penetration but decreases cleaning eect.
4. DC- (or DC+) (direct current)
Hot Start time for the 2T function (H2t 0.1 s…5.0 s, factory setting 1.0 s). Can be seen only on
the 2T function. You can see recommended diameter for electrode by pressing QUICK SETUP
-button. Diameter depends on current adjustment.
HF/contact ignition in TIG welding (water ll)
TIG arc can be started either with high frequency (HF) or with contact ignition. HF ignition is
chosen by pressing the HF CONTACT button to turn on the HF light.
If you use water-cooled torch you can ll it with water by pressing the HF CONTACT button for
more than 2 seconds. The display reads ’COOLER’.
EN
Welding torch switch 2T function
Gas ow starts when the torch switch is pressed. Welding starts, and the current will rise to
the Hot Start current within the up-slope time, remain at that level for the set time (H2t) and
then change to the welding current. The Hot Start function can be disabled and green panel
light switches o when the Hot Start current is adjusted to 100 %. The current will then rise
directly to the welding current level within the up-slope time. Release the torch switch, and
the current starts to drop, and after the selected down-slope time the arc is broken. After this,
the shield gas will ow for the time selected.
Welding torch switch 4T function
Gas ow starts when the torch switch is pressed. Release the torch switch. The ignition spark
ignites the arc, and the current will rise to the Hot Start current within the up-slope time. You
can switch from Hot Start current to welding current with a short press of the torch switch.
You can disable the Hot Start function by adjusting the Hot Start current to 100 %. The current
will then rise directly to the welding current level within the up-slope time.
Press the torch switch down, and the welding continues. Release the torch switch, and the
current starts to drop and after the selected down-slope time the arc is broken. After this, the
shield gas will ow for the time selected.
Remote control
If you choose to adjust the welding current with a remote control unit you need to connect
the unit and select the remote control selection button. The PANEL light switches o, and
you can select the unit (R10, foot pedal control R11F, or torch control). The foot pedal control
works only in 2T mode. Hold the remote control selection button (LO/HI) down to adjust the
limits of the remote control’s adjustment range.
14
Adjustment of parameters
To select TIG welding parameters you only need to use two buttons: arrow-left and arrowright. Red panel light shows parameter you have chosen. Adjustment is done with the control
knob. When pressing the RETURN button, adjustment of parameters goes straight to welding
current. The display shows automatically numeric values and the units of the parameters.
When you adjust the parameters, you can see the value on the numerical display. After 10
seconds, the display will return to the welding current.
Welding panel ACX
– pulsed TIG and MINILOG function with memory
2.
3. 4. 7. 8.
1.
9.
11.
5.
10.
MasterTig MLS 3000, 3003 ACDC / © Kemppi Oy / 1112
6. 12. 13.
1. 4T-LOG and MINILOG function selections
2. Search arc 5 – 90 % of welding current
3. Start-current 80 – 150 %
4. Minilog-current 10 – 150 % of welding current
5. Tail arc 5 – 90 % of welding current
6. Selection for spot, synergetic quick pulse, long pulse and MicroTack
7. Spot time 0.0 – 10.0 s
8. Pulse current 10 A – power source max.
9. Pulse ratio 10 – 70 % of pulse time
10. Frequency 0.2 – 250 Hz DC-TIG, 0.2 – 20 Hz AC-TIG
11. Pause current 10 – 70 % of pulse current
12. MEMORY, memory function
13. Selection of channel in memory function
14. SAVE/memory values
If wanted in SETUP-function you can disable search arc and tail arc functions. Hot Start (Soft
Start)- and Minilog -currents can be disabled by adjusting the values to 100 per cent (the same
as the welding current).
14.
EN
15
MasterTig MLS 3000, 3003 ACDC / © Kemppi Oy / 1112
Minilog
When torch switch is pressed gas ow starts. When you release the torch switch current goes
to Search Arc. By pressing shortly the switch current goes through upslope to Hot Start or Soft
Start current depending on adjustments and by pressing shortly again to welding current.
After next short press it goes to Minilog current, 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 the torch switch. Press the torch switch for one second, release it and current goes to
downslope and the arc is cut.
4T-LOG
When torch switch is pressed current goes to search arc; after the switch is released current
goes to welding current within the upslope time. When the switch is pressed again, current
goes to downslope and then to the tail arc. Current stops when the switch is released.
Synergic quick pulse (SYNERGIC)
Press the PULSE button (6) until the synergic light turns on. Pulse parameters are adjusted
automatically when average welding current is selected. Other pulse selections are not
necessary.
Long pulse (PULSE)
Long pulse method (button 6/PULSE) gives you the possibility to adjust all pulse parameters
(pulsing frequency, pulse ratio, pulse current and pause current). You can also adjust the
welding current, in which case you receive a new pulse current value. Pulse ratio and pause
current percentage remain constant. When you adjust the pulse current the new average
welding current value is shown on the display.
EN
Spot welding function (SPOT)
The function (button 6/SPOT) can be used both in 2T and 4T mode. Enter the spot duration
by pressing arrow button, and when the led is lit you can choose the spot time needed by
turning the pulse control knob.
TIG -Micro tack welding function (MicroTack™)
You can select the MicroTack function with a long press of the MicroTack arrow button (6) and
MicroTack light turns on, the machine automatically enables the DC- welding mode, 2T switch
mode and contact ignition. This function can also be used with HF ignition, 4T mode and on
AC welding. To inactivate the MicroTack you press briey the same arrow button (6).
The duration of the spot weld (SPt) can be adjusted by pressing Quick Setup button and
selecting a value in the range 1–200 ms. Also on AC welding the amount of spots (Pco) can be
adjusted between 1 – 5.
The spot current can normally be adjusted with the control knob when the welding current
led is on.
MicroTack adjustments can be saved to memory channel according the next advise.
3.2.3 Saving welding settings
ACX panel has 10 memory channels for user settings. The selections are made in the MEMORY
eld. Not only welding parameters but also function selections can be saved in the memory.
MMA welding values can also be stored in memory channels. Proceed as follows:
1. Press MEMORY button and if the SET light starts blinking the channel is free. If a channel is in
use, the ON light will light up. Press again, and the SET light will be continuously lit.
2. Select memory channel by pressing CH button.
3. Select the parameters and press SAVE button.
4. Press MEMORY button twice. ON led is lit.
5. Start welding.
If the saved settings need to be adjusted the led has to be moved from ON to SET position in
order to select parameters. Press the SAVE button.
When the memory function is in OFF state (no lights on) it is also possible to save the currently
used panel parameters by pressing SET/SAVE, by choosing channel ja by pressing SET/SAVE
again. Channel is cleared if MEMORY and CH buttons are pressed simultaneously in SET mode.
16
3.2.4 Adopting the saved settings
1. Select MEMORY by pressing the button.
2. Select memory channel by pressing the CH button.
3. Start welding.
3.2.5 Remote control memory channels
Memory channels are selected by pressing simultaneously both REMOTE and CH button. With
the remote control you can retrieve saved settings on memory channels 1-5. The selected
channel is marked with a dot.
3.2.6 SETUP functions
A so called SETUP state is included for modifying panel functions. You can enter the SETUP
state by pressing the SETUP button longer than normally. Exit is performed in the same way.
You can select the function (see list below) by pressing the arrow buttons and then change
the setting by turning the control knob. See SETUP-function table on the next page.
3.2.7 Foot pedal control R11F
First read ”ACS Welding Panel – Basic Functions” point ”Remote control” for installing the
remote control ready for operation. Foot pedal R11F is used in TIG welding, and its control
range is adjustable. The minimum value of control range is set with the panel control knob
when the pedal is not pressed, display shows ”LO”. Control range maximum is set similarly by
pressing rst the PEDAL LO/HI button on the panel, display shows ”HI”. Welding is started with
a light press on the pedal, the arc ignites to the set minimum current. Welding current goes
to maximum when the pedal is pressed to the bottom. The arc is broken when the pedal is
released. Adjust again if necessary.
MasterTig MLS 3000, 3003 ACDC / © Kemppi Oy / 1112
3.3 COOLING UNIT OPERATION MASTERCOOL 30
The operation of Mastercool cooling unit is controlled by the power source. The cooling unit
pump starts automatically when welding starts. Proceed as follows:
1. Start power source.
2. Check water level and input ow of the reservoir, add liquid if needed.
3. If you use a water-cooled torch you can ll it with water by pressing WATER FILL button for
more than 2 seconds.
The pump operates for 4 another minutes after welding has been nished to cool the water to
the same temperature as in the machine surrounds. This reduces the need of service.
Thermal overload
The thermal overload light is lit, the machine stops and display shows COOLER when
temperature control of the machine has detected cooling water overheating. The cooling unit
fan cools down the water, and when the light goes out welding can be started again.
Water ow signal
Display shows COOLER when water ow is blocked.
3.4 STORAGE
The machine must be stored in a clean and dry room. Protect the machine from rain and direct
sunshine in places where temperature exceeds +25 °C.
EN
17
3.5 SETUPFUNCTIONS
EN
MasterTig MLS 3000, 3003 ACDC / © Kemppi Oy / 1112
SETUP-function Display
Upslope current dependency
A1 ON The upslope time is determined by the current.
(*C)
Downslope current
A2 ON The downslope time is determined by the current.
dependency (*C)
TIG Antifreeze (*C)
MMA Antifreeze (*C)
VRD (*C)
2T downslope cut off
Tacking automatics
Limitation of rate of current
A3 ON TIG Antifreeze on.
A4 ON MMA Antifreeze on.
A7 ON VRD mode: idle voltage < 35 V
A8 ON In 2T mode, cut o the downslope with a quick push of the start
A9 ON If welding has lasted less than 3 seconds, no downslope when
A10 ON If the current is over 100 A and UpSlope is 0.0 sec., there is a 0.2-
rise with high currents
MMA/TIG method selection
A12 ON TIG = the start of remote control scale.
with remote control (C*)
SearchArc On/Off
Current freeze function
Memory channel selection with
A13 ON SearchArc on.
A14 ON During the slope, the current can be ‘frozen’ at a certain level (4T
A15 ON The Plus/Minus buttons on the remote control RTC20 can be used
Plus/Minus buttons (C*)
Activation of the Plus/Minus
A16 ON The Plus/Minus remote control (RTC20) is always active.
buttons (C*)
Water cooler flow guard (C*)
Water cooler automatic control
A17 ON Flow guard on.
A19 ON Automatic control on.
(C*)
Water cooler temperature
A20 ON Water cooler temperature guard selected.
guard (C*)
Automatic remote control
A21 ON Automatic recocnition on, control cannot be selected if it is not
device recognition (C*)
Tail arc
A22 ON* Tail arc on. * 4T LOG
*C = Common: applies to all memory channels
Factory setting with a grey background
OFF The upslope time remains as set.
OFF The downslope time remains as set.
OFF TIG Antifreeze o.
OFF MMA Antifreeze o.
OFF Normal idle voltage (3000: 63 V, 3003: 58 V)
button.
OFF Quick push has no eect.
welding is stopped.
OFF Tacking automatics o.
second slope from half the welding current.
OFF Current rises directly to indstillet værdi.
MMA = the end of the scale.
OFF Remote control as a normal current regulator.
OFF SearchArc o.
and Minilog) by pushing the start button.
OFF Freeze function o.
to select the memory channel.
OFF The buttons adjust the current.
OFF The Plus/Minus remote control is active only when selected by
pressing the REMOTE button.
OFF Flow guard o.
OFF Water cooler runs constantly.
OFF Temperature guard o.
connected.
OFF Automatic recocnition On/O. Controller can be selected even if it
is not connected.
OFF** Tail arc o. ** MINILOG
18
3.6 ERROR CODES
The machine always checks its operation automatically during start-up and reports any
failures detected. If failures are detected during start-up, they are shown as error codes on the
control panel display.
Err3: Overvoltage, undervoltage or phase loss
The machine has stopped the welding because it has detected momentary voltage spikes or
continuous mains over- or under-voltage dangerous to the machine, or a phase loss in the
mains voltage. Check the quality of the supply network.
Err4: Power source overheating
The power source has overheated. The cause may be one of the following:
• The power source has been used for a long time at maximum power.
• The circulation of cooling air to the power source is blocked.
• The cooling system has experienced a failure.
Remove any obstacle to air circulation, and wait until the power source fan has cooled down
the machine.
Other error codes:
The machine can show codes not listed here. In the event of an unlisted code appearing,
contact an authorised Kemppi service agent and report the error code shown.
4. MAINTENANCE
NOTE! Watch out for mains voltage when handling electric cables!
Degree and circumstances of machine utilisation should be taken into consideration when
planning product maintenance. Careful use and preventive maintenance help to avoid
unnecessary production disturbances and breaks. Check the condition of the welding and
connection cables daily. Do not use damaged cables.
4.1 REGULAR MAINTENANCE
4.1.1 Every sixth months
NOTE! Disconnect the plug of the machine from the mains socket and wait for ca. 2 minutes
(capacitor charge) before removing the casing plate.
The following maintenance operations should be carried out at least every sixth
months:
• Electric connections of the machine - clean any oxidised parts and tighten any loose
ones.
NOTE! You must know the correct tension torques before you start repairing the connections.
• Clean the inner parts of the machine from dust and dirt e.g. with a soft brush and a
vacuum cleaner. Do not use compressed air because there is the danger that the dirt
is packed even more tightly in the gaps of the cooling proles. Do not use a pressure
washer.
NOTE! Only an authorised electrician may repair the machine.
MasterTig MLS 3000, 3003 ACDC / © Kemppi Oy / 1112
EN
4.1.2 Service contract
KEMPPI service workshops make special service contracts with customers about regular
maintenance. All parts are cleaned, checked and if necessary, repaired. Also the operation of
welding machine is tested.
19
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 earth clamp is properly fastened and that earth cable has no defects. Change
the position if necessary and replace defect parts.
• Check welding torch cable and connector. Tighten the connection and replace defective
parts.
• Check the consumable parts of welding torch. Clean and replace defect parts.
• Check mains fuses, replace blown fuses.
Power source overheat indicator light is lit.
Power source is overheated.
• Check that there is enough free space behind the machine for cooling air circulation.
MasterTig MLS 3000, 3003 ACDC / © Kemppi Oy / 1112
• Check cooling unit for water circulation, clean cooling unit lter and air grate. Add
cooling liquid if necessary.
For further information and assistance, contact your nearest Kemppi service workshop.
EN
4.3 DISPOSAL OF THE MACHINE
Do not dispose of electrical equipment with normal waste!
In observance of European Directive 2002/96/EC on waste electrical and electronic
equipment, and its implementation in accordance with national law, electrical equipment
that has reached the end of its life must be collected separately and taken to an appropriate
environmentally responsible recycling facility.
The owner of the equipment is obliged to deliver a decommissioned unit to a regional
collection centre, per the instructions of local authorities or a Kemppi representative. By
applying this European Directive you will improve the environment and human health.
5. ORDERING NUMBERS
Power sources
Mastertig MLS™ 3000 ACDC 6163000
Mastertig MLS™ 3003 ACDC 6163003
Mastertig MLS™ 3000 ACDC VRD 6163000VRD
Panels
ACS 6162805
ACX 6162804
20
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 627016008
TTC 160 16 m 627016016
TTC 220 4 m 627022004
TTC 220 8 m 627022008
TTC 220 16 m 627022016
Gas ow meter AR/clock 6265136
Cooling unit
Mastercool 30 6163900
Water-cooled torches
TTC 200W 4 m 627020504
TTC 200W 8 m 627020508
TTC 200W 16 m 627020516
TTC 250W 4 m 627025504
TTC 250W 8 m 627025508
TTC 250W 16 m 627025516
Optional device
TIG torch controls
RTC 10 6185477
RTC 20 6185478
Remote control
R 10 6185409
R11F 6185407
Transport unit
T130 6185222
T110 6185251
T100 6185250
T200 6185258
MasterTig MLS 3000, 3003 ACDC / © Kemppi Oy / 1112
EN
21
EN
6. TECHNICAL DATA
Power source MasterTIG MLS™ 3000 ACDC
Connection voltage
Rated power at maximum current
Connection cable
Fuse, delayed
Load capacity 40 °C
Welding range
Max. welding voltage
MasterTig MLS 3000, 3003 ACDC / © Kemppi Oy / 1112
Open circuit voltage
Idle power
Power factor at max. current
Efficiency at max. current
Striking voltage
Stick electrode
External dimensions
Weight
50/60 Hz 3~400 V -10 %…+10 %
TIG 13.3 kVA
MMA 14.4 kVA
H07RN-F 4G2.5 (5 m)
16 A
40 % ED TIG 300 A/13.3 kVA
60 % ED TIG 230 A/9.8 kVA
100 % ED TIG 190 A/7.9 kVA
40 % ED MMA 250 A/14.4 kVA
60 % ED MMA 230 A/13.3 kVA
100 % ED MMA 190 A/11.0 kVA
TIG 3 A/10.0 V-300 A/22 V
MMA 10 A/20.5 V-250 A/30 V
MMA 45 V/250 A
63 V DC (VRD: 35 V DC)
TIG < 13 W
MMA 190 W
0.62
83 %
80 %
Up = 10 kV
ø 1.5...5.0 mm
LxWxH 500x180x390 mm
height 650 mm (power source + cooling unit)
23 kg
22
Power source and cooling unit
EMC-class
Degree of protection
Operating temperature
Storage temperature
Recommended generator
A
IP23S
-20 °C .... +40 °C
-20 °C .... +60 °C
S
15 kVA
min
Power source MasterTIG MLS™ 3003 ACDC
Connection voltage
Rated power at maximum current
Connection cable
Fuse, delayed
Load capacity 40 °C
Welding range
Max welding voltage
Open circuit voltage
Idle power
Power factor at max. current
Efficiency at max. current
Striking voltage
Stick electrode
Minimun short circuit power Ssc of
50/60 Hz 3~230 V -10 % ... 460 V +10 %
TIG 9.2 kVA
MMA 10.0 kVA
H07RN-F 4G2.5 (5 m)
20/16 A
40 % ED TIG 300 A 9.2 kVA
60 % ED TIG 230 A 6.2 kVA
100 % ED TIG 190 A 4.8 kVA
40% ED MMA 250 A 10.0 kVA (230 VAC 30 %)
60 % ED MMA 230 A 8.8 kVA
100 % ED MMA 190 A 7.0 kVA
TIG 3 A/10 V – 300 A/22 V
MMA 10 A/20.5 V – 250 A/30 V
MMA 35 – 45 V/250 A
58 V DC
TIG < 10 W
MMA 160 – 180 W
0.95
80 – 84 %
77 – 81 %
Up = 10 kV
ø 1.5...5.0 mm
1.2 MVA
supply network*
External dimensions
Weight
LxWxH 500x180x390 mm
height 650 mm (power source + cooling unit)
25 kg
MasterTig MLS 3000, 3003 ACDC / © Kemppi Oy / 1112
EN
Power source and cooling unit
EMC-class
Degree of protection
Operating temperature
Storage temperature
Recommended generator
* See paragraph 2.7.2.
A
IP23S
-20 °C .... +40 °C
-20 °C .... +60 °C
S
20 kVA
min
23
MasterTig MLS 3000, 3003 ACDC / © Kemppi Oy / 1112
Cooling unit (TIG-welding) Mastercool 30
Operating voltage
Cooling power
Connection capacity
Maximum pressure
Cooling liquid
Tank volume
External dimensions
Weight
100 % ED 50 W
24 V DC
1.0 kW
4.0 bar
20 % – 40 % glycol-water
approx. 3 l
LxWxH 500x180x260 mm
8 kg
EN
24
MasterTig MLS 3000, 3003 ACDC / © Kemppi Oy / 1112
EN
25
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