Kemppi MASTERTIG AC/DC 2000, Operation Instructions Manual

Page 1: ...MASTERTIG AC DC 2000 2500 2500W 3500W Operation instructions english Gebrauchsanweisung deutsch Gebruiksaanwijzing nederlands Manuel d utilisation français 1916200E 0510 ...

Page 2: ... 3 4 8 Adjustment of the form of the arc BALANCE 17 3 4 9 Frequency adjustment of TIG AC welding only with minilog and pulse panel 18 3 4 10 Minilog operation only with minilog and pulse panel 18 3 4 11 Pulse welding only with the pulse panel 19 3 4 12 Control of the start current only with the pulse panel 19 3 4 13 Fusion spot welding only with a pulse panel 19 3 5 Memory functions only with the ...

Page 3: ...t Kemppi distributor The specifications and designs presented in this manual are subject to change without prior notice In this document for danger to life or injury the following symbol is used Read the warning texts carefully and follow the instructions Please also study the Operation safety instructions and respect them when installing operating and servicing the machine 1 2 PRODUCT INTRODUCTION...

Page 4: ...hine inside a work piece eg container or truck Do not place welding machine on a wet surface Always check cables before operating the machine Change damaged cables without delay Damaged cables may cause an injury or set out a fire Connection cable must not be crushed it must not touch sharp edges or hot work pieces Welding power circuit Isolate yourself by using proper protective clothing do not we...

Page 5: ...astertig AC DC 2500 2 INSTALLATION 2 1 CABLING THE MACHINE Shielding gas hose Gas cooled TIG torch Cable for MMA welding Return current cable Remote control unit Mains cable Shielding gas hose Cable for MMA welding Remote control unit Gas cooled TIG torch Return current cable Mains cable ...

Page 6: ...PPI OY Mastertig AC DC 2500W Mastertig AC DC 3500W Shielding gas hose Cable for MMA welding Remote control unit Return current cable Water cooled TIG torch Cable for MMA welding Remote control unit Return current cable Shielding gas hose Water cooled TIG torch ...

Page 7: ...nt of and at the rear of the machine for the circulation of the cooling air Protect the machine against heavy rain and in hot circumstances against direct sunshine 2 3 START OF INSTALLATION Mastertig AC DC 2500 and 2500W Check first that the mains voltage change over switch is in right position If it is necessary to change mains cable do it before moun ting to the wheel barrow T 120 Otherwise you p...

Page 8: ...500W and 3500W The machine is delivered with a 5 m mains cable 4 2 5 mm2 without a plug Mains cable is suitable for all mains voltages with recommended fuse size please look at Technical data table 4 6 mm2 cable can be connected to the machine if local regulations are requiring it If you use greater fuse size than recommended big short circuit current can cause extra damage in case of failure Mast...

Page 9: ...cially in AC welding and decreases the ignition spark Clean the fastening surface of any paint and rust 2 6 THE WELDING TORCH In Mastertig AC DC 2000 and Masterig AC DC 2500 only an gas cooled torch can be used In Mastertig AC DC 2500 W and 3500W you can use either an gas cooled or a water cooled torch Make sure that the torch you are using is designed for the maximum welding current that you need...

Page 10: ...harpened and a rounded cut electrode When welding starts the machine will round the cut tip so that its is suitable The current range of the electrode is extended the current of the lower end is lowered and the current of the maximum end is increased With BALANCE automatics you can use the position for a sharpened electrode with a narrower arc to obtain a narrower seam and to a deeper penetration ...

Page 11: ...nut C with a wrench 5 Install hose spindle D and jacket nut E into gas hose and tighten with hose clamp 6 Connect the hose with the regulator and the other end with the wire feed unit 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 ...

Page 12: ...12 Mastertig AC DC 2000 2500 2500W 3500W 0510 COPYRIGHT KEMPPI OY 12 13 14 6 5 4 3 1 22 21 19 11 12 13 14 6 5 4 3 2 1 22 21 20 19 3 OPERATING PANELS BASIC MINILOG ...

Page 13: ...stment of the frequency FREQUENCY 0 1 300 Hz 10 Adjustment of the start current starting with a current lower than the welding current SOFT START or with a current higher than the welding current HOT START 70 50 11 Selection of Minilog operations and adjustment of the current level MINILOG 80 20 12 Adjustment of the pre gas time and at the same time the key for code locking CODE LOCK 13 Adjustment...

Page 14: ...you can adjust the welding current of MMA and TIG welding The values of the parameters up slope and down slope times gas flow times etc are adjusted from the current knob With remote control unit C 100AC you can also change the welding method MMA TIG The machine selects the polarity type of current in accordance with an advance selection on the panel 3 3 MMA WELDING 3 3 1 Selection of type of curre...

Page 15: ... You can change the type of current by pressing the selection key again If you want to select DC as the current type for TIG press both TIG keys at the same time 3 4 2 Spark ignition Use contact ignition when you are welding in a environment where there are sensitive electronic equipements The ignition spark can cause interferences in equipement near the welding machine The arc is ignited with a h...

Page 16: ...nite and the welding current will rise to the welding level within the selected up slope time 4 Release the torch switch and the welding current will drop in accordance with the selected down slope time After the arc is turned off the shielding gas will continue to flow for the post gas time The down slope time of the welding current can be interrupted by quickly pressing the torch switch You can g...

Page 17: ...rrent The adjustment of the down slope time is done from the poten tiometer The time can be adjusted between 0 15 s When you adjust the down slope time you can see the time in seconds in the right hand numerical display After 5 seconds the display will return to the start status 3 4 6 Adjustment of the up slope time of the welding current 1 Press the key next to the up slope of the current pattern...

Page 18: ...urrent and the base current and you can move from one to the other by quickly pressing the torch The Minilog operation can be used only with a 4 function torch switch operation The selection and adjustment of the Minilog operation is done by means of the potentiometer When the potentiometer is in the OFF position the operation is not in use The welding current is selected from the current knob lik...

Page 19: ...s of the control potentiometer of the start current you can select either a soft normal or hot start The start current is available only with a 4 function torch switch operation By turning the potentiometer to OFF you have a normal start see the use of the torch switch 4 function By turning the potentiometer to the left you get a soft start SOFT START When you raise the torch switch the current ri...

Page 20: ... the values 3 5 2 Saving a welding situation parameters in the memory 3 5 1 Calling the values from the memory 1 Press the CHANNEL key so many times that the numerical channel display shows the number of the channel that you want At the same time the signal lights of the panel show you the selections of the selected channel and the current display shows you the set value 1 Press the SAVE key once ...

Page 21: ... that you have installed in order to be able to use the machine 1 Feed in the first digit from the current adjustment knob 2 Accept the digit by pressing REMOTE CODE LOCK ENTER 3 Feed in the second and third digits in the same way The machine is ready for use If you enter wrong code you can try again by turning the machine off and on If you can not open the machine you do not remember the right cod...

Page 22: ...a long time with a current higher than 100 of the duty cycle or when the circulation of the cooling air is prevented 5 2 OVER VOLTAGE PROTECTION OF THE MAINS SUPPLY VOLTAGE If the over voltages in the mains supply are so high that they can endanger the machine the supply of the machine is immediately turned off If the over voltages are short in duration this may be seen as short breaks in the curr...

Page 23: ...e control and start connections in the rear of the power source When using the foot pedal unit the maximum current output of the machine is ca 30 below its maximum output unless the machine is calibrated for the foot pedal unit 6 1 2 Calibration of the machine for the foot pedal unit 1 Turn the machine off 2 Press the REMOTE key and at the same time turn the machine on the display will show the te...

Page 24: ...s not in use J04 On manual AC balance control Off balance function in use J05 On tag welding automatics is not in use Off tag welding automatics on J06 On down slope of TIG is minimum end level current Off end level current is 20 of the welding current J07 Off open circuit voltage is 70 V On open circuit voltage is 12 V without VRD card 22 V with VRD card J08 On when stopping welding with 4T funct...

Page 25: ... electrode are undamaged and that the electrode is tightly fastened in its place 8 1 2 The torch cable Check that the insulation of the handle and the torch cable are undamaged the torch cable has no sharp bends Always replace any damaged parts immediately Follow the instructions of the torch manufacturer in all maintenance and repair measures 8 2 CABLES Check the condition of the welding and conn...

Page 26: ...AINTENANCE KEMPPI Service Repair Shops handle regular maintenance by agreement Regular maintenance includes e g the following Cleaning of the machine Checking and maintenance of the welding tools Checking the clamps switches and potentiometers Checking the electric connections Checking the mains cable and plug Replacement of any parts that are damaged or in poor condition Maintenance testing The o...

Page 27: ... 160 4 m 627066004 TTK 160 8 m 627066008 TTK 160 16 m 627066016 TTK 160S 4 m 627066204 TTK 160S 8 m 627066208 TTK 160S 16 m 627066216 TTK 220 4 m 627072004 TTK 220 8 m 627072008 TTK 220 16 m 627072016 TTK 220S 4 m 627072304 TTK 220S 8 m 627072308 TTK 220S 16 m 627072316 TIG torches water cooled TTK 250WS 4 m 627075704 TTK 250WS 8 m 627075708 TTK 250WS 16 m 627075716 TTK 300W 4 m 627080504 TTK 300W...

Page 28: ...ED T 40 C MMA 60 ED T 40 C MMA 100 ED T 40 C AC and DC fixed adjustable length width height 230 V 10 200 A 6 8 kVA 150 A 4 5 kVA 160 A 7 3 kVA 100 A 4 2 kVA 3 A 10 V 200 A 18 V 10 A 10 V 200 A 18 V 10 A 10 V 160 A 26 4 V 11 A 10 V 160 A 26 4 V 3 x 2 5 mm2 S 3 16 A delayed 200 A 18 V 150 A 16 V 160 A 26 4 V 100 A 23 6 V 20 A delayed 200 A 18 V 150 A 16 V 160 A 26 4 V 140 A 23 6 V 70 V DC 60 Hz 50 20...

Page 29: ... V 400 V 460 V TIG DC AC MMA TIG AC 60 ED 70 ED 100 ED MMA DC 40 ED 100 ED TIG AC 100 ED MMA DC 80 ED 100 ED AC and DC fixed adjustable length width height 230 V 10 400 V 10 460 V 10 250 A 7 5 kVA 200 A 6 7 kVA 250 A 10 3 kVA 200 A 7 9 kVA 4 x 2 5 mm2 S 5 m 20 A delayed 16 A delayed 16 A delayed 3 A 10 V 250 A 20 V 10 A 10 V 250 A 20 V 10 A 20 V 250 A 30 V 250 A 20 V 220 A 18 8 V 250 A 30 V 200 A 2...

Page 30: ...11 7 kVA 280 A 8 2 kVA 350 A 15 7 kVA 280 A 11 2 kVA 4 x 2 5 mm2 S 5 m 20 A delayed 3 A 10 V 350 A 24 V 10 A 10 V 350 A 24 V 10 A 20 V 350 A 34 V 350 A 24 V 280 A 21 2 V 350 A 34 V 280 A 31 2 V 310 A 22 4 V 350 A 34 V 300 A 32 V 70 V DC 60 Hz 50 200 Hz 80 350 A 34 V 0 9 350 A 34 V 18 W 40 60 C 20 40 C B 130 C H 180 C IP 23C 690 mm 260 mm 870 mm 74 kg 350 kPa 1300 W 3 50 60 Hz TIG 60 ED TIG 100 ED ...

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