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Technical data
Mains Voltage
Mains cable
Fuse
Rated power
40%
TIG
MMA
300A
250A
100%
TIG
MMA
Minimum Current
58 V
0,95
80-84 % (250A / 30V)
77-81 % (300A / 22V)
TIG < 13W
MMA 190W
1,5 - 5,0 mm
500 x 180 x 390 mm
25 kg
190A
190A
Maximum power can be achieved with 20 kVA generator for the power source.
User interface
7
8.
3.
4.
5.
2.
1.
6.
1.
2.
3.
4.
5.
6.
7.
8.
Error code
Description
Err 3
Overvoltage
Err 4
Over heating
Err 6
Err 8
Maximum overheat time, machine doesnt cool down fast enough. Only machine
shutdown and restart removes error.
Err 61
COO Ler
Cooler error:
- Cooling liquid over- / under pressure state
- Overheated alarm
BuS Err
Err rSt
Setup functions
Entering the advanced setup press and hold the setup and Return buttons at the same
time. Changing the level press Setup button shortly
Welding current upslope time *
TIG Antifreeze *
MMA Antifreeze *
VRD ***
(MMA open circuit voltage)
Tacking automatics
ON
OFF
ON
OFF
ON
TIG Antirfeeze is ON
OFF
ON
MMA antifreeze is ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
A1
A2
A3
A4
A7
A8
A9
A10
A12
* Setting is always on ** Adjustable also by the Quick Setup *** Requires VRD card
Setup functions
Start current level
Current freezing
A13
A17
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
Controlled run
OFF
Continous run
ON
OFF
ON
Automatic detection is ON
OFF
ON
OFF
NOR
GRN
A15
A16
A14
ON
A19
A20
A21
A22
A23
* Setting is always on ** Adjustable also by the Quick Setup ***Depends on panel software version
Setup functions
20
Contact ignition current *
B1
B2
B3
32
30
1.0
0.2
2.
0
10
54
0
OFF
Factory setting
PAN
ALL
B5
B6
B7
B8
B9
Factory setting 20 A
OFF
Factory setting
05
0
0.4
0.3
1.
0
OFF
ON
Post-running time 30 s.
Setup functions
B10
OFF
ON
0150 s.
0
MMA dynamics **
B11
90
9
0
MMA ignition pulse **
B12
90
9
10
B13
B14
B15
Factory setting
Adjustment range -9 = soft arc, 9 = rough arc
Factory setting
Adjustment range -9 = minimum overrun, 9 =
maximum overrun
Factory setting 10 % of the welding current
OFF
Minimum current
54
0
5.0
1.0
20
,0
1.0
0.1
5.
0
Setup functions
AC balance minimum *
C1
C7
C16
0.0
0.0
2.
0
1.0
01
0
-80
80
-10
1
Pregas time maximum *
D1
01
0
30
D7
15
150
10
AC balance maximum *
D16
02
0
Factory setting 1 s.
Adjustment range 010 s.
Factory setting 30 s.
Adjustment range 15150 s.
Factory setting 10 %
Adjustment range 0120 %
Setup functions
60
AC frequency **
E1
AC waveform **
E2
50250
E3
Square wave
Sin
Sinus wave
520
-25
AC balance **
E4
-5010
100
Negative ignition current *
E5
100500
50
Positive ignition current *
E6
30150
10
E7
E8
E9
Factory setting 5 A
Adjustment range 520 A
Factory setting -25 %
Adjustment range -5010 %
020
0.20
Setting 0,20 s.
0.011,0
0.6
MIX TIG cycle time **
Sqr
5
Half cycle AC
Factory setting 60 Hz
0.11,0
Factory setting
Adjustment range 0,11,0 s.
* Setting is always on ** Adjustable also by the Quick Setup *** Note panel software version
Setup functions
50
MIX TIG AC pulse ratio **
E10
E11
10
90
100
50
150
10
Spotwelding time *
E12
Factory setting 50 %
12
00
10
Construction
L002
A003
Z002
Spark
transformer
Fans
Z004
Main transformer
Shunt resistor
P001
Z001
Under insulator
A004
A001
A002
PVC insulator
Water cooler
connectors
11
12
13
14
15
X17 (1-4)
no faults
X17 (2-5)
no freq. sweep
X17 (3-6)
pfc on
H1 reference
no visual meaning
16
X9
X11
X5
X4
X17
H4 = gate drive on
X18
H2 = output over
X1
voltage
Factory settings
- X16 = off
- X14 = off
- X20 = off
H8 = secondary dc-
H10 = HF (spark)
H9 = secondary aid+
- X19 = on
- R108 = 25kHz
X2
X12
H6 = secondary dc+
X3
X8
X6
X7
H7 = +24Vdc
X10
H5 = +5Vdc
17
Factory setting
X17 = off
18
R27
R27 == HF
HF voltage
voltage adjusting
adjusting
range
range (8.5
(8.5 .... 13)kV
13)kV
19
20
Measurements
Z001, Main circuit card :
- Power should be off !
- With these measurements you can find short circuits and partly open circuits that indicates fault in
the machine.
- Measure diodes in forward and reverse direction. Forward diode threshold voltage is ~0,4V, reverse
direction infinite. See the picture below for instructions.
- Repeat measurements for all four (4) instances. Pin locations marked in the pictures below.
- Remember that MLS 3000 ACDC and 3003 ACDC have different Z001 cards !
10
12
14
Diode 2.
Diode 2.
1.
2.
17
Diode 3.
3.
22
4.
24
Diode 3.
Diodes*
Measuring points
Value
1.
2 -> 22
~ 0,4 V
2.
8 -> 12
~ 0,4 V
3.
24 -> 17
~ 0,4 V
4.
10 -> 14
~ 0,4 V
21
Measurements
Z004 Pre-inverter, rectifier:
- Power should be off !
- With these measurements you can find short circuits and partly open circuits that indicates fault in
the machine.
- Measure diodes in forward and reverse direction. Forward diode threshold voltage is ~0,5V, reverse
direction infinite. See the picture below for instructions.
- Repeat measurements for all six (6) instances. Pin locations marked in the pictures below.
Diode 1.
Diode 1.
1
X1
1.
2.
3.
X2
4.
5.
6.
Diode 4.
X3
Diode 4.
Diodes*
Measuring points
Value
1.
X1 -> 1
~ 0,5 V
2.
3 -> X1
~ 0,5 V
3.
X2 -> 1
~ 0,5 V
4.
3 -> X2
~ 0,5 V
5.
X3 -> 1
~ 0,5 V
6.
3 -> X3
~ 0,5 V
22
Measurements
Z004 Pre-inverter, IGBT:
- Power should be off !
- With these measurements you can find short circuits and partly open circuits that indicates fault in
the machine.
- Measure diodes in forward and reverse direction. Forward diode threshold voltage is ~0,4 V, reverse
direction infinite.
- Measuring points have been marked in the picture below. Four (4) measurements must be
conducted to be sure of correct operation of Z004.
Diode 1.
2.
Diode 1.
14
1.
10
12
3.
4.
17
4
Diode 3.
22
24
Diode 3.
Diodes*
Measuring points
Value
1.
8 -> 12
~ 0,4 V
2.
2 -> 22
~ 0,4 V
3.
4 -> 14
~ 0,4 V
4.
4 -> 17
~ 0,4 V
23
Measurements
Z003 Secondary inverter
- Power should be off
- Measure diodes and IGBTs in forward and reverse direction. Forward diode threshold voltage is
about 0,45V, reverse direction high.
- C-A, C-E, B-C, D-B, ~0,45V diode threshold voltage
B-E, 0,7V diode threshold voltage
D-C, 0,85V diode threshold voltage
A (in+, heat sink)
D (aux-)
B (in-)
E (aux+)
C (out+-)
24
Measurements
These tests have to be done after replacing any primary or
secondary units. It absolutely important because possible short
circuit (e.g. improperly installed mica insulator) might damage
machine severely.
TESTING OF THE CONTROL CARD AND CONTROL CIRCUITS
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
If current is over the limit you can disconnect other connectors from A001 to
check where current using circuit is.
You can test cooling fans and gas valve by connecting A001/X9
(Current limit needs to be about 1A)
Turn off machine and disconnect power supply.
Connect A001/X7.
Restore jumpers and wires.
25
Measurements
TESTING OF THE POWER STAGE
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
X5 = - 9 11 Vdc
X9
X5
X8
X7
26
Measurements
TESTING OF THE PRE-INVERTER (PFC)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
X4
X8
X17/1-4
X17/3-6
27
Measurements
TESTING OF THE SECONDARY OVER VOLTAGE WATCH
1.
2.
3.
4.
5.
24 VDC
PTC
24 VDC
50 VDC
PTC
28
Installation of semiconductors
IGBT mounting onto the heat sink
The installation surfaces must be clean, even very small particles (0,050mm) between the surfaces
increase the gap between heat sink and module, causing module overheating and possibly
destruction. Heat transfer paste is spread as an even layer about 0,1 mm thick, onto the modules
base plate. The module is immediately attached to the heat sink, in order to avoid any dirt to get
between the components. At first all M5 screws are tightened carefully to torque of 0,52 Nm, after
which the module can be tightened to the nominal torque of 3 Nm. After a few minutes the screw
torques are checked again to be 3 Nm.
Secondary unit
As described above but screws are torx T-10 and tightening torque 1,2 Nm. Diodes and discrete
IGBTs can be tighten right away to this torque.
29
Installation of semiconductors
Secondary rectifier Z002
Negative side diodes are
insulated from the heat sink by
mica insulators. Mica insulators
have to be replaced always,
when the secondary diode card
Z002 is separated from heat
sink !!!
30
Installation of semiconductors
Secondary inverter Z003
Negative side IGBTs are
insulated from the heat sink by
mica insulators. Mica insulators
have to be replaced every time
the main circuit card Z003 is
disconnected from heat sink !!!
Heat transferring paste is
applied as thin layers on both
sides of the mica insulators.
Absolutely no impurities are
allowed on surface of the
insulators when mounting them
between the heat sink and the
IGBTs!
31
Notes
32