Kemppi MLS 3000 User Manual

MLS 3000, 3003 ACDC

MasterTig

MLS 3000 ACDC VRD

Operating manual • English

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OPERATING MANUAL

English

MasterTig MLS 3000, 3003 ACDC / © Kemppi Oy / 1112

CONTENTS

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

1. PREFACE

1.1 GENERAL

Congratulations on your choice of the Kemppi MasterTig MLS ACDC welding system. Reliable and durable, Kemppi products are aordable 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 specications 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 specications 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 eort 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 specication 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

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 specic 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

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

Installing water-cooled torch

Connect the red water hose to the upper connector and blue one to the lower connector.

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,

continue gently pushing the upper part of the panel until it clips into place. Finally, push the xing pin back into its place.

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.

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.

Mastercool 30

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