Kemppi DC 2000 User Manual

Mastertig

aC/DC 2000, 2500, 2500W, 3500W

1916200E

0701

2 – Mastertig aC/DC 2000, 2500, 2500W, 3500W/0701 © keMppi oy

CONTENTS

1. PREFACE ........................................................................................................................ 3

1.1. Introduction .......................................................................................................................3

1.2. Product introduction ..........................................................................................................

1.3. Operation safety ................................................................................................................

2. INSTALLATION ............................................................................................................... 5

2.1. Cabling the machine .........................................................................................................5

2.2. Siting the machine .............................................................................................................

2.3. Start of installation .............................................................................................................

2.4. Connecting the machine to the mains supply ...................................................................

2.5. Cable for MMA welding and return current cable ..............................................................

2.6. The welding torch ..............................................................................................................

2.7. Electrodes to be welded ....................................................................................................

2.8. TIG DC welding .................................................................................................................

2.8.1. Sharpening of the electrode ............................................................................................ 9

2.9. TIG AC welding ...............................................................................................................10

2.9.1. Balance .........................................................................................................................10

2.10. Shield gas ....................................................................................................................... 11

2.10.1. Installing gas bottle ....................................................................................................... 11

3. OPERATING PANELS ..................................................................................................12

3.1. Numerical displays and signal lights of the panel ...........................................................14

3.2. Use of the remote control ................................................................................................

3.3. MMA welding ...................................................................................................................

3.3.1. Selection of type of current ........................................................................................... 14

3.3.2. Broken arc method ........................................................................................................

3.3.3. Control of MMA welding dynamics (only with minilog and pulse panels) ......................

3.4. TIG welding .....................................................................................................................15

3.4.1. Selection of TIG welding and type of current ................................................................ 15

3.4.2. Spark ignition ................................................................................................................

3.4.3. Contact ignition .............................................................................................................

3.4.4. Use and selection of operation of the torch switch ........................................................

3.4.5. Adjustment of the down-slope time of the welding current ............................................

3.4.6. Adjustment of the up-slope time of the welding current ................................................

3.4.7. Adjustment of the pre-gas and post-gas times ..............................................................

3.4.8. Adjustment of the form of the arc, BALANCE ...............................................................

3.4.9. Frequency adjustment of TIG AC welding (only with minilog and pulse panel) ............

3.4.10. Minilog operation (only with minilog and pulse panel) ...................................................

3.4.11. Pulse welding (only with the pulse panel) .....................................................................

3.4.12. Control of the start current (only with the pulse panel) ..................................................

3.4.13. Fusion spot welding (only with a pulse panel) ...............................................................

3.5. Memory functions (only with the pulse panel) .................................................................20

3.5.1. Calling the values from the memory .............................................................................. 20

3.5.2. Saving a welding situation (parameters) in the memory ...............................................

3.6. Code locking ...................................................................................................................20

3.6.1. Installing the code locking ............................................................................................. 21

3.6.2. Turning the machine on when the code locking is on ...................................................

3.6.3. Removal of code locking ...............................................................................................

3.6.4. Changing the code ........................................................................................................

4. COOLING UNIT (ONLY MASTERTIG AC/DC 2500W, -3500W) .................................. 22

5. INTERNAL PROTECTIONS OF THE MACHINE ..........................................................

5.1. Overheating protection .................................................................................................... 22

5.2. Over-voltage protection of the mains supply voltage ......................................................

5.3. The wrong voltage selection ...........................................................................................

5.4. Protection of a water-cooled torch ..................................................................................

6. ACCESSORIES ............................................................................................................. 23

6.1. Remote control units ....................................................................................................... 23

6.1.1. Connecting the foot pedal unit ...................................................................................... 23

6.1.2. Calibration of the machine for the foot pedal unit ..........................................................

6.2. Wheel barrows and transport chassises ......................................................................... 23

7. EXTRA FUNCTIONS ..................................................................................................... 24

8. MAINTENANCE ............................................................................................................

8.1. The welding torch ............................................................................................................ 25

6.1.1. The welding end ............................................................................................................ 25

6.1.2. The torch cable .............................................................................................................

8.2. Cables .............................................................................................................................25

8.3. The power source ...........................................................................................................

8.4. Regular maintenance ......................................................................................................

9. OPERATION DISTURBANCES ....................................................................................26

10. DISPOSAL OF THE MACHINE .....................................................................................

11. ORDERING NUMBERS ................................................................................................

12. TECHNICAL DATA ........................................................................................................

13. TERMS OF GUARANTEE .............................................................................................

Mastertig aC/DC 2000, 2500, 2500W, 3500W/0701 – 3© keMppi oy

GH 20

C 100AC C 100F

ACDC minilog

ACDC pulse

ACDC panel

TTK 160

TTK 220

TTK 350W

1. PREFACE

1.1. INTRODUCTION

Congratulations on having purchased this product. Properly installed Kemppi products should prove to be productive machines requiring maintenance at only regular intervals. This manual is arranged to give you a good understanding of the equipment and its safe operation. It also

contains maintenance information and technical specications. Read this manual from front to back before installing, operating or maintaining the equipment for the rst time. For further

information on Kemppi products please contact us or your nearest Kemppi distributor.

The specications 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

Mastertig AC/DC is a power source for TIG /MMA welding suitable for AC and DC welding and designed for demanding professional use. The power source is an inverter, which is formed with IGB transistors. The power source is available in three sizes, 200 A, 250 A and 350 A. The 250 A power source comes in two separate versions for gas-cooled torches and for water-cooled torches. Three different exchangeable panel versions are available for the power source: a basic

panel, a minilog panel and a pulse panel.

4 – Mastertig aC/DC 2000, 2500, 2500W, 3500W/0701 © keMppi oy

1.3. OPERATION SAFETY

Please study these Operation safety instructions and respect them when installing, operating and

servicing the machine.

Welding arc and spatters

Welding arc hurts unprotected eyes. Be careful also with reecting arc ash. Welding arc and

spatter burn unprotected skin. Use safety gloves and protective clothing.

Danger for re or explosion

Pay attention to re safety regulations. Remove ammable or explosive materials from welding place. Always ensure that you have sufcent re ghting equipment available where you are welding. Be prepared for hazards in special welding jobs, eg. for the danger of re or explosion when welding container type work pieces. Note! Fire can break out from sparks even several hours after the welding work has been nished!

Mains voltage

Never take welding machine 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 re. 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 wear wet clothing. Never work on a wet surface or use defect cables. Do not put the TIG torch or welding cables on welding machine or on other electric equipment. Do not press the TIG torch switch, if the torch is not directed towards a work piece.

Welding fumes

Take care that there is sufcient ventilation during welding. Take special safety precautions when welding metals which contain lead, cadmium, zinc, mercury or beryllium.

This equipment’s electromagnetic compatibility (EMC) is designed for use in an industrial environment. Class A equipment is not intended for use in residential location where the electrical power is provided by the public low-voltage supply system.

Mastertig aC/DC 2000, 2500, 2500W, 3500W/0701 – 5© keMppi oy

Mastertig AC/DC 2000

Mastertig 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

6 – Mastertig aC/DC 2000, 2500, 2500W, 3500W/0701 © keMppi 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

Mastertig aC/DC 2000, 2500, 2500W, 3500W/0701 – 7© keMppi oy

2.2. SITING THE MACHINE

When siting the machine, the following have to be considered:

Site the machine on a xed dry base, which does not cause dust etc. into the suction air of

cooling.

– Make sure that the machine is placed away from the line of particle spray from grinding

tools.

– Ensure free circulation of the cooling air. Make sure that there is at least a 20 cm free dis

tance both in front 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 rst that the mains voltage change-over switch is in right position.

If it is necessary to change mains cable, do it before mounting to the wheel barrow T 120. Otherwise you possibly

have to dismount the machine.

Before connecting the machine to the mains supply, one

of the three panels, the ACDC panel, the ACDC minilog or the ACDC pulse panel, has to be installed. Installation

instructions 4283280 are in the package of the panel.

2500, 2500W, 3500W

2.4. CONNECTING THE MACHINE TO THE MAINS SUPPLY

The installation or replacement of the mains cable and the plug may be carried out only by an authorized electric shop or electrician.

Mastertig AC/DC 2000

The machine is delivered with a mains cable with an earthed plug for connection to a mains supply of 230 V.

To be noted when replacing the mains cable:

The lifting handles, cover and the right-hand-side plate have to be opened. The cable in brought to the machine through the inlet ring on the rear panel and fastened with a cable clamp. The phase lead of the cable are coupled to connector L, the blue to the connector of the N lead and the yellow-green to the connector of the protective grounding lead .

Mastertig AC/DC 2500, -2500W 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.

Mastertig AC/DC 2500, -2500W

Before connecting the machine to the mains supply, make sure that the voltage change-over switch of the machine is turned to the position corresponding to the mains supply voltage (230 / 400 / 460 V).

When replacing the mains cable, note the following:

The lifting handles, cover and right-hand-side plate of the machine have to be opened. The cable is brought to the machine through the inlet right on the rear panel and fastened with a cable clamp. The phase leads of the cable are coupled to connectors L1, L2 and L3; the yellow-green

is coupled to the connector of the protective grounding lead .

Reference max electrode diameters and yield electrode type yield 2000 2500, 2500W 3500W

Fe-rutile 95 % ø 4 ø 5 ø 6 Fe-base 100 % ø 4 ø 5 ø 6 Fe-high-yield 180 % ø 2,5 ø 4 ø 5 250-270 % - - - ø 4 ø 5 Ss-rutile - - - ø 4 ø 6 ø 6 Ss-base - - - ø 4 ø 6 ø 6 Ss-high-yield 150 % ø 3,25 ø 5 ø 6 Hard facing by welding 100 % ø 3,25 ø 5 ø 6

2.5. CABLE FOR MMA WELDING AND RETURN CURRENT CABLE

The welding cables have to be at least 16 mm2 copper cables for Mastertig AC/DC 2000 and 25

mm2 copper cables for Mastertig AC/DC 2500, Mastertig AC/DC 2500W and 50 mm2 copper

cables for Mastertig AC/DC 3500W. Thinner cables will cause voltage losses and heating.

Connect the grounding clamp of the return cable carefully, preferably directly to the piece to be

welded. Use as short welding cables as possible. Unnecessarily long cables will lower the maximum output voltage of the machine. Coiling of the excess cable lowers the output voltage of the machine especially 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.

Never use a damaged torch!

2.7. ELECTRODES TO BE WELDED

With the Mastertig AC/DC power sources you can use all electrodes designed for DC or AC welding within the current limits of the machine in question.

Mastertig AC/DC 2500, -2500W and -3500W power sources are suitable for carbon arc gouging and cutting according to their maximum power.

2.8. TIG DC WELDING

DC– current is used typically when welding different kind of steel. We rekommend for DC– welding a WC20 (grey) elctrode.

2.8.1. Sharpening of the electrode

The tip of the electrode is sharpened into a cone, so that the arc becomes steady and the thermal

energy is concentrated on the spot being welded. The length of the sharpening to the diameter of the electrode:

with small current sharp l = 3 x d

with large current blunt l = 1 x d

Choice of the electrode for DC welding. The table is only given as a guide.

2.9. TIG AC WELDING

AC-current is typically used when welding aluminium. We recommend for AC-welding a WC20 (grey) or a clean wolfram electrode (green).

2.9.1. Balance

In AC-welding the ratio between the positive and negative half-cycle is called balance. With the balance you can control heat between the electrode and work piece. When balance is positive, it means that the positive half-cycle is longer than the negative, more heat is coming to the electrode than to the work piece. Correspondingly when balance is negative, negative half-cycles are longer, the work piece is hotter and the electrode is colder. Mastertig AC/DC-machines have build-in BALANCE-automatism, which chooses automatically right balance value. User adjusts the BALANCE-knob according to the electrode, and the machine takes care of the balance

control in different currents.

BALANCE automatics offers two benets as compared to a constant balance:

– In AC welding, you can use both a sharpened 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 than with a rounded electrode. A narrow seam is useful especially in llet welding.

When using a rounded electrode, the arc is broad and the cleaning area of the arc is

also wider, so it can be used for end-to-end seams and outer corners.

The table is only given as a guide.

The table and the panel scale are based on the use of WC20 (grey). When using pure wolfram electrode (green) the tip rounds off slightly.

Welding current range Electrode Gas nozzle Gas ow rate

DC- WC20 Argon

A ø mm number 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...350 3,2 7/8 11,0/12,5 8...10

330...350 4 10 16 10...12

Welding current range

Electrode Gas nozzle Gas ow rate

min. min. max.

WC20 Argon

A A A ø mm number ø mm 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

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