Manual - Plasmaserv
Contents
1. Front of machine 1 Pow ov pa Function panel Remote control connector TIG torch control connector Shieldgasandcurrentconnectorfor TIG torch connectorforelectrodeholder connector for earth cable Markings for poles on the machine front are embossed Installing gas cooled torch le Connect the red water hose to the upper connector and blue one to the lower connector Rear of machine T 2 Mains switch Snap connector for gas MasterTig MLS 3000 3003 ACDC Kemppi Oy 1112 EN MasterTig MLS 3000 3003 ACDC Kemppi Oy 1112 EN 2 5 2 6 2 7 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 fixing 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 fixing pin back into its place MAINS CONNECTION NOTE Only an authorised electrician is allowed to i2. 22 19 Regular maintenance neig es ee ee Ge 19 42 Troubleshoot serye senine n 20 4 3 Disposal of the machine 20 5 ORDERING 5 20 6 TECHNICAL DATA blanda tomates een oe SN 22 1 1 1 2 PREFACE GENERAL Congratulations on your choice of the Kemppi MasterTig MLS ACDC welding system Reliable and durable Kemppi products are affordable 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 specifications of the device can be found at the end of the manual Please read the manual carefully before using the equipment for the first 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 specifications 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 VOTE notation Read these sections carefully and follow their instructions Disclaimer While every effort has been made to ensure t
3. KEMPPI The Joy of Welding MasterTig MLS 3000 3003 ACDC MLS 3000 ACDC VRD Operating manual English K ytt ohje Suomi Bruksanvisning Svenska Bruksanvisning Norsk Brugsanvisning Dansk Gebrauchsanweisung Deutsch Gebruiksaanwijzing Nederlands Manuel d utilisation Francais Manual de instrucciones Espa ol Instrukcja obstugi Polski no rh x Manual de utiliza o Portugu s Manuale d uso Italiano EN FI SV DA DE NL FR ES PL RU ZH PT IT ZLLL O ddway o DADY 00 000 SIW OPERATING MANUAL English MasterTig MLS 3000 3003 ACDC Kemppi Oy 1112 EN CONTENTS jJ PREFACE tonta m Su Duss 3 RE OE IE ER EE OE EE 3 1 0 Introduction u u Ed m ee Ee Ge 3 2 5 2222 2222 4 21 Removal from packaging on auper egi 4 22 Locating the machine eens ER Ge Ee Epiese ska Rek tdt esed 4 23 Seral DUITIDBE Ee ese 4 24 Installation and main parts escasos trementes tinte enit 4 2 5 Installation of the panel tine aderire E rbi t eek erani 6 2 6 Mains COnNNECt DEI a AE EE EE EE N i iisip 6 27 Distribution ie ie ag cum oe ee 6 28 Welding cable connections eene
4. can be used for electrode welding when MMA welding is selected 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 WQ0 Argon Vw min 15 25 90 1 6 4 5 6 6 5 8 0 9 5 6 7 20 30 150 24 6 7 9 5 11 0 7 8 30 45 200 3 2 7 8 10 110 125 16 8 10 40 60 350 4 0 10 11 16 17 5 10 12 The table and the panel scale based on the use of WC20 grey TIG Welding with Direct Current DC welding is typically used when welding different 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 00 L Argon H A mm number l min 5 80 1 0 4 5 6 5 8 0 5 6 70 140 1 6 4 5 6 65 80 95 6 7 140 230 24 6 7 9 5 11 0 7 8 225 330 3 2 7 8 10 11 0 12 5 16 8 10 3 1 4 3 1 5 3 1 6 3 1 7 3 1 8 3 2 3 2 1 3 2 2 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 we
5. 1 4 1 1 4 1 2 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 Thecirculation 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 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 n
6. EDTIG 100 EDTIG 40 ED MMA 6096 ED MMA 10096 ED MMA TIG MMA MMA TIG MMA LxWxH height MasterTIG MLS 3003 ACDC 3 230V 10 460 V 10 96 9 2 KVA 10 0 kVA 462 5 5 m 20 16 A 300 9 2 kVA 230 6 2 kVA 190 A 4 8 kVA 250 A 10 0 kVA 230 Vac 30 96 230 A 8 8 kVA 190 A 7 0 kVA 3A 10V 300 22 10 A 20 5 V 250 A 30 V 35 45 250 58V DC lt 10W 160 180 W 0 95 80 8496 77 81 Up 10 kV 61 5 5 0mm 1 2 500x180x390 mm 650 mm power source cooling unit 25 kg A 235 20 C 40 C 20 C 60 C Smin 20 KVA 23 MasterTig MLS 3000 3003 ACDC Kemppi Oy 1112 EN MasterTig MLS 3000 3003 ACDC Kemppi Oy 1112 EN 24 Cooling unit TIG welding Operating voltage Cooling power Connection capacity Maximum pressure Cooling liquid Tank volume External dimensions Weight 100 ED LxWxH Mastercool 30 24V DC 1 0 kW 50W 4 0 bar 20 40 glycol water approx 3 1 500x180x260 mm 8kg ZLLL O ddwy o DADY 00 000 SIW EN 25 KEMPPI OY Hennalankatu 39 PL 13 FIN 15801 LAHTI FINLAND Tel 358 3 899 11 Telefax 358 3 899 428 export kemppi com www kemppi com Kotimaan myynti Tel 358 3 899 11 Telefax 358 3 734 8398 myynti fi kemppi com KEMPPI SVERIGE AB Box 717 5 194 27 UPPLANDS V SBY SVERIGE Tel 46 8 590 783 00 Telefax 46 8 590
7. TIG Antifreeze off MMA Antifreeze on MMA Antifreeze off VRD mode idle voltage lt 35V Normal idle voltage 3000 63 V 3003 58 V In 2T mode cut off the downslope with a quick push of the start button Quick push has no effect If welding has lasted less than 3 seconds no downslope when welding is stopped Tacking automatics off If the current is over 100 A and UpSlope is 0 0 sec there is a 0 2 second slope from half the welding current Current rises directly to indstillet v rdi TIG the start of remote control scale MMA the end of the scale Remote control as a normal current regulator SearchArc on SearchArc off During the slope the current can be frozen at a certain level AT and Minilog by pushing the start button Freeze function off The Plus Minus buttons on the remote control RTC20 can be used to select the memory channel The buttons adjust the current The Plus Minus remote control RTC20 is always active The Plus Minus remote control is active only when selected by pressing the REMOTE button Flow guard on Flow guard off Automatic control on Water cooler runs constantly Water cooler temperature guard selected Temperature guard off Automatic recocnition on control cannot be selected if it is not connected Automatic recocnition On Off Controller can be selected even if it is not connected Tail arc on 4T LOG Tail arc off MINILOG 3 6 4
8. 823 94 sales se kemppi com KEMPPI NORGE A S Postboks 2151 Postterminalen N 3103 TONSBERG NORGE Tel 47 33 346000 Telefax 47 33 346010 sales no kemppi com KEMPPI DANMARK A S Literbuen 11 DK 2740 SKOVLUNDE DANMARK Tel 45 4494 1677 Telefax 45 4494 1536 sales dk kemppi com KEMPPI BENELUX B V Postbus 5603 NL 4801 EA BREDA NEDERLAND Tel 31 765717750 Telefax 31 765716345 sales nl kemppi com www kemppi com KEMPPI UK Ltd Martti Kemppi Building Fraser Road Priory Business Park BEDFORD MK44 3WH UNITED KINGDOM Tel 44 0 845 6444201 Telefax 44 0 845 6444202 sales uk kemppi com KEMPPI FRANCE S A S 65 Avenue de la Couronne des Pr s 78681 EPONE CEDEX FRANCE Tel 33 1309004 40 Telefax 33 130 90 04 45 sales fr kemppi com KEMPPI GmbH Otto Hahn StraBe 14 D 35510 BUTZBACH DEUTSCHLAND Tel 49 6033 88 020 Telefax 49 6033 72 528 sales de kemppi com KEMPPI SPOLKA Z 0 0 Ul Borzymowska 32 03 565 WARSZAWA POLAND Tel 48 22 7816162 Telefax 48 22 7816505 info pl kemppi com KEMPPI AUSTRALIA PTY LTD 13 Cullen Place PO Box 5256 Greystanes NSW 2145 SMITHFIELD NSW 2164 AUSTRALIA Tel 61 2 9605 9500 Telefax 61 2 9605 5999 info au kemppi com 000 KEMPPI Polkovaya str 1 Building 6 127018 MOSCOW RUSSIA Tel 7 495 739 4304 Telefax 7 495 739 4305 info ru kemppi com 000 yn 1 6 127018 Tel 7 495 739 4304 Telefa
9. cate 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 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 alumini
10. cator lights 1 Power On 2 Thermal overload of power source 3 Wrong mains voltage over or under voltage 11 MasterTig MLS 3000 3003 ACDC Kemppi Oy 1112 EN MasterTig MLS 3000 3003 ACDC Kemppi Oy 1112 EN 12 ACS welding panel basic functions 12 13 14 15 16 17 KEMPPI 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 GASTEST button 11 Control knob for welding parameter adjustment 12 5 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 indi
11. ctor at max current Efficiency at max current Striking voltage Stick electrode External dimensions Weight Power source and cooling unit EMC dass Degree of protection Operating temperature Storage temperature Recommended generator 22 50 60 Hz TIG MMA HO7RN F 40 EDTIG 60 100 96 ED TIG 40 ED MMA 60 96 ED MMA 100 ED MMA TIG MMA MMA TIG MMA LxWxH height MasterTIG MLS 3000 ACDC 3 400V 10 10 13 3 14 4 482 5 5 m 16A 300 A 13 3 230 A 9 8 kVA 190 A 7 9 kVA 250 A 14 4 230 A 13 3 190 A 11 0 kVA 3 A 10 0 V 300 A 22 V 10 A 20 5 V 250 A 30 V 45 V 250A 63 V DC VRD 35 V DC 13W 190 W 0 62 83 80 96 Up 10 kV 0 1 5 5 0 mm 500x180x390 mm 650 mm power source 4 cooling unit 23 kg A 235 20 C 40 C 20 C 60 C Smin 15 KVA Power source Connection voltage Rated power at maximum current Connection cable Fuse delayed Load capacity 40 C Welding range Max welding voltage 0pen circuit voltage Idle power Power factor at max current Efficiency at max current Striking voltage Stick electrode Minimun short circuit power Ssc of supply network External dimensions Weight Power source and cooling unit EMC class Degree of protection Operating temperature Storage temperature Recommended generator See paragraph 2 7 2 50 60 Hz TIG MMA HO7RN F 40 EDTIG 60
12. hat 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 specification 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 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 water cooled 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 ope
13. ing 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 itis 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 Is wm 3 2 4 3 2 5 3 2 6 3 2 7 3 3 3 4 Adopting the saved settings 1 Select MEMORY by pressing the button 2 Select memory channel by pressing the CH button 3 Start welding 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 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 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 adjustab
14. lding speed 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 Spot welding function In spot welding function you can to adjust the duration of the welds in the range 0 10 s MicroTack function MicroTack welding is an efficient way to connect thin materials together using low heat input which decreases distortions in base material TIG welding with mixed AC DC current MIX Especially joining aluminium materials of different thicknesses can best be made out by using mixed current Adjust values with SETUP function if needed OPERATION FUNCTIONS Power source NOTE Always switch the machine on and off 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 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 Indi
15. le 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 first the PEDAL LO HI button on the panel display shows 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 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 flow of the reservoir add liquid if needed 3 Ifyou use a water cooled torch you can fill it with water by pressing WATER FILL button for more than 2 seconds The pump operates for 4 another minutes after welding has been finished 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 flow signal Display shows COOLER when water flow is blocked STORAGE The machine must be stored in a c
16. lean and dry room Protect the machine from rain and direct sunshine in places where temperature exceeds 25 C 17 MasterTig MLS 3000 3003 ACDC Kemppi Oy 1112 EN MasterTig MLS 3000 3003 ACDC Kemppi Oy 1112 EN 3 5 18 SETUP FUNCTIONS SETUP function Upslope current dependency 0 Downslope current dependency C TIG Antifreeze C MMA Antifreeze C VRD C 2T downslope cut off Tacking automatics Limitation of rate of current rise with high currents MMA TIG method selection with remote control C SearchArc On Off Current freeze function Memory channel selection with Plus Minus buttons C Activation of the Plus Minus buttons C Water cooler flow guard C Water cooler automatic control Water cooler temperature guard C Automatic remote control device recognition C Tail arc Display M A2 M N A9 A10 12 A13 14 15 16 17 19 20 A21 A22 ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF Common applies to all memory channels Factory setting with a grey background The upslope time is determined by the current The upslope time remains as set The downslope time is determined by the current The downslope time remains as set TIG Antifreeze on
17. n circuit voltage under 35 V MasterTig MLS 3000 3003 ACDC Kemppi Oy 1112 EN MasterTig MLS 3000 3003 ACDC Kemppi Oy 1112 EN 2 1 2 2 2 3 2 4 INSTALLATION 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 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 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 specific product It is important to make correct reference to the serial number of the product when making repairs or ordering spare parts INSTALLATION AND MAIN PARTS
18. n 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 flow 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 off 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 Adjustment of parameters To select TIG welding parameters you only need to use two buttons arrow left and arrow right 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
19. ng 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 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 s
20. ng unit 2 10 SHIELD GAS 2 10 1 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 flow regulator is suitable for the gas type used The flow rate is set according to the welding current joint form and the size of the electrode A suitable flow rate is normally 8 10 l min If the gas flow is not suitable the welded joint will be porous Spark ignition becomes more difficult if the gas flow is too high Contact your local Kemppi dealer for choosing gas and equipment Parts of gas flow regulator gt Gas bottle valve Pressure regulation screw Connecting nut Hose spindle Jacket nut Gas bottle pressure meter Gas hose pressure meter Installation of gas bottle NOTE Always fasten gas bottle properly in vertical position in a special holder on the wall or on a carriage Remember tto close gas bottle valve after having finished welding The following installation instructions are valid for most gas flow regulator types 1 Step aside and open the bottle valve A fora while to blow out possible impurities from the bottle valve Note Watch out for the gas flow 2 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 regulat
21. nstall mains cable and plug The machine is equipped with a five 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 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 2 8 1 2 8 2 2 9 WELDING CABLE CONNECTIONS The welding cables must be made of at least 25 mm copper cable Choosing welding polarity in MMA welding You can select the polarity elect
22. 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 SW DV th r w N gt 14 If wanted in SETUP function you can disable search arc and tail arc functions Hot Start Soft MICROTACK SPOT r SYNERGIC 4T LOG and MINILOG function selections Search arc 5 90 of welding current Start current 80 150 Minilog current 10 150 of welding current Tail arc 5 90 96 of welding current Selection for spot synergetic quick pulse long pulse and MicroTack Spot time 0 0 10 0 s Pulse current 10 A power source max Pulse ratio 10 70 96 of pulse time Frequency 0 2 250 Hz DC TIG 0 2 20 Hz AC TIG Pause current 10 70 96 of pulse current MEMORY memory function Selection of channel in memory function SAVE memory values Start and Minilog currents can be disabled by adjusting the values to 100 per cent the same as the welding current 15 MasterTig MLS 3000 3003 ACDC Kemppi Oy 1112 EN MasterTig MLS 3000 3003 ACDC Kemppi Oy 1112 EN 3 2 3 16 Minilog When torch switch is pressed gas flow 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 pressi
23. or 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 filled when the bottle pressure is 2 bar 8 Open needle valve if there is one in the regulator 9 Turnregulation screw B until hose pressure meter G showsthe requiredflow or pressure When regulating flow amount the power source should be switched on and the gun switch pressed simultaneously Close bottle valve after having finished welding If the machine will be out of use for a long time unscrew the pressure regulation screw MasterTig MLS 3000 3003 ACDC Kemppi Oy 1112 EN MasterTig MLS 3000 3003 ACDC Kemppi Oy 1112 EN 3 1 3 1 1 3 1 2 3 1 3 10 OPERATION NOTE Welding in places presenting an immediate fire or explosion hazard is forbidden NOTE Welding fumes may cause injury take care of sufficient ventilation during welding WELDING PROCESSES 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
24. or power supply is insufficient Check welding settings and adjust if needed Check gas flow 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 e 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 Check cooling unit for water circulation clean cooling unit filter and air grate Add cooling liquid if necessary For further information and assistance contact your nearest Kemppi service workshop 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 impro
25. ot use damaged cables REGULAR MAINTENANCE Every sixth months NOTE Disconnect the plug ofthe 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 profiles Do not use a pressure washer NOTE Only an authorised electrician may repair the machine 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 MasterTig MLS 3000 3003 ACDC Kemppi Oy 1112 EN MasterTig MLS 3000 3003 ACDC Kemppi Oy 1112 EN 4 2 4 3 20 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
26. pot 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 briefly 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 Saving welding settings ACX panel has 10 memory channels for user settings The selections are made in the MEMORY field 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 andi if the SET light starts blinking the channel is free Ifa channel is in use the ON light will light up Press again and the SET light will be continuously lit Select memory channel by pressing CH button Select the parameters and press SAVE button Press MEMORY button twice ON led is lit 5 Start weld
27. requency 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 affects 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 effect for DC TIG current types 13 MasterTig MLS 3000 3003 ACDC Kemppi Oy 1112 EN 2 Kemppi Oy 1112 MasterTig MLS 3000 3003 ACDC EN 14 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 AC time AC 10 90 factory setting 50 Cycle time CYc 0 1 1 0 s factory setting 0 6 s DC current DC 50 150 96 factory setting 100 96 Balance BAL 50 0 10 96 factory setting 25 90 Frequency FrE 50 250 Hz factory setting 60 Hz Selection of AC waveform sine or square wave SinuS SquArE Hot Start time for the 2T function H2t 0 1 s 5 0s factory setting 1 0s Canbeseenonly on the 2T function Factory setting i
28. ronically 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 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 firmly 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 MasterTig MLS 3000 3003 ACDC Kemppi Oy 1112 EN MasterTig MLS 3000 3003 ACDC Kemppi Oy 1112 EN Installation of cooling unit Electrical connection for the cooling unit 1 Control connector 2 Protective earth NOTE Onlyan authorised electrician is allowed to install electrical connection See the mounting instructions delivered with the cooli
29. s marked with a dot after the numeric value Growing DC current increases penetration but decreases cleaning effect 4 DC or DC direct current Hot Start time for the 2T function H2t 0 1 5 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 D Dy HF contact ignition in TIG welding water fill 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 fill it with water by pressing the HF CONTACT button for more than 2 seconds The display reads COOLER Welding torch switch 2T function Gas flow 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 off 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 flow for the time selected Welding torch switch 4T function Gas flow starts whe
30. ttrmsiteseittsuceei tertiae tik 7 29 Cooling unit to Mastercool 30 sse 7 2 10 Shield aas 9 3 OPERATION a ee Re ee Re ee Re ee ee ee 10 3 1 Welding processes GE ER n ee ee denda 10 3 1 1 Welding is ESE EE OE EED eer ge ee 10 3 1 2 TIG welding Alternating Current ee ee ee ee RR Ge ee RR ee ee Re ee ee Re 10 3 1 3 TIG Welding with Direct 10 3 1 4 Synergetic Pulsed TIG welding ee ee ee ee Re ee RR ee ee Re ee Re 11 3 1 5 Long Pulsed TIG welding 11 3 1 6 Spot welding function sse 11 3 1 7 MierolaekWf neti nma u na nalan tette ee ee ee ee 11 3 1 8 TIG welding with mixed AC DC current MIX 11 32 Operation functions nda PRO PEDRO UR nee 11 32 POWBLSOUTCe S oe muna asa ORE 11 3 22 Function panels iode ee bee ES Su rn iei e Ree 11 3 2 3 Saving welding settings sss 16 3 24 Adopting the saved settings 17 3 25 Remote control memory channels 17 326 SETUP f etl nssu u y unu nine E HO RR HER ERR 17 3 27 Foot pedal control 1 17 3 3 Cooling unit operation Mastercool 30 17 34 SONG n NE EE OE RE 17 3 5 SETUP functions u u Ge Ge 18 50 usada E bn Ie Ee EE 19 4
31. um 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 50 0 factory setting 25 90 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 Effect of the balance adjustment A positive balance value breaks up aluminium oxide more effectively 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 fillet 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 f
32. ve the environment and human health ORDERING NUMBERS Power sources Mastertig MLS 3000 ACDC 6163000 Mastertig MLS 3003 ACDC 6163003 Mastertig MLS 3000 ACDCVRD 6163000VRD Panels ACS 6162805 ACX 6162804 Cabels Welding cable 16mm 5m Welding cable 25 mm 5 Welding cable 25 mm 10m Welding cable 35 mm 5 Earth cable 16 mm 5 Earth cable 25 mm 5 Earth cable 25 mm 10m Earth cable 35 mm 5 Torches TIC 160 4m TIC 160 8m TIC 160 16m TIC 220 4m TIC 220 8m TIC 220 16m Gas flow meter AR clock Cooling unit Mastercool 30 Water cooled torches TIC200W 4m TIC200W 8m TIC200W 16m TIC250W 4m TIC250W 8m TIC250W 16m Optional device TIG torch controls RIC 10 20 Remote control R10 RIF Transport unit T130 T110 T100 T200 6184103 6184201 6184202 6184301 6184113 6184211 6184212 6184311 627016004 627016008 627016016 627022004 627022008 627022016 6265136 6163900 627020504 627020508 627020516 627025504 627025508 627025516 6185477 6185478 6185409 6185407 6185222 6185251 6185250 6185258 21 MasterTig MLS 3000 3003 ACDC Kemppi Oy 1112 EN MasterTig MLS 3000 3003 ACDC Kemppi Oy 1112 EN 6 TECHNICAL DATA Power source 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 fa
33. x 7 495 739 4305 info ru kemppi com KEMPPI TRADING BEIJING COMPANY LIMITED Room 420 3 Zone Building B No 12 Hongda North Street Beijing Economic Development Zone 100176 Beijing CHINA Tel 86 10 6787 6064 86 10 6787 1282 Telefax 86 10 6787 5259 sales cn kemppi com BAD 165 ARAA X ZR ERR 12 5 fil Bt KBR 420 100176 86 10 6787 6064 86 10 6787 1282 86 10 6787 5259 sales cn kemppi com KEMPPI INDIA PVT LTD LAKSHMI TOWERS New No 2 770 First Main Road KAZURA Gardens Neelangarai CHENNAI 600 041 TAMIL NADU Tel 91 44 4567 1200 Telefax 91 44 4567 1234 sales india kemppi com 0700161
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