Kemppi DC 3500W User Manual
MASTERTIG AC/DC
MASTERTIG AC/DC
9901
Operation instructions
MASTERTIG AC/DC 1600 1~ 230 V
MASTERTIG AC/DC 2500 3~ 230 V / 400 V / 460 V
MASTERTIG AC/DC 2500W 3~ 230 V / 400 V / 460 V
MASTERTIG AC/DC 3500W 1~ 400 V
1916110E
English
Read carefully these instructions before you use the welding machine !
Bitte, lesen Sie diese Gebrauchsanweisungen vor Gebrauch der Schweiß-
maschine !
Lees deze gebruiksaanwijzing aandachtig door voor u de lasmachine in
gebruik neemt !
Veuillez lire et appliquer ces instructions avant utilisation de la machine!
English
OPERATION SAFETY............................................. 3
TERMS OF GUARANTEE....................................... 3
1. GENERAL .......................................................... 4
2. INSTALLATION OF THE MACHINE ...................5
2.1 Cabling the machine ....................................5
2.2 Siting the machine ....................................... 7
2.3 Start of installation ....................................... 7
2.4 Connecting the machine to the mains supply .. 7
2.5 Cable for MMA welding and return
current cable ................................................ 8
2.6 The welding torch ........................................ 8
2.7 Electrodes to be welded ..............................8
2.8 TIG DC welding ........................................ 8
2.9 TIG AC welding ............................................8
2.10 Shielding gas ............................................. 9
2.11 Gas flow regulator ...................................... 9
3. OPERATING PANELS ...................................... 10
3.1 Numerical displays and signal lights
English
of the panel ............................................... 12
3.2 Use of the remote control .......................... 12
3.3 MMA welding ............................................. 12
3.4 TIG welding ............................................... 12
3.5 Memory functions
(only with the pulse panel) ......................... 16
3.6 Code locking .............................................. 16
4. COOLING UNIT
(only Mastertig AC/DC 2500W, -3500W) .......... 18
5. INTERNAL PROTECTIONS OF THE MACHINE.. 18
5.1 Overheating protection .............................. 18
5.2 Over-voltage protection of the mains
supply voltage ............................................ 18
5.3 The wrong voltage selection ...................... 18
5.4 Protection of a water-cooled torch ............. 18
6. MAINTENANCE ............................................... 18
6.1 The welding torch ...................................... 18
6.2 Cables ....................................................... 19
6.3 The power source ...................................... 19
6.4 Regular maintenance ................................19
7. OPERATION DISTURBANCES ........................ 19
8. ACCESSORIES................................................ 19
8.1 Remote control units.................................. 19
8.2 Wheel barrows and transport chassises ....20
9. EXTRA FUNCTIONS ........................................ 20
10. TECHNICAL DATA .........................................21
2 / 1916110E / 9901
OPERATION SAFETY
Never watch the arc without a face shield designed for arc welding!
The arc damages unprotected eyes!
The arc burns unprotected skin!
Be careful for reflecting radiation of arc!
Protect yourself and the surroundings against the arc and hot spray!
Dont use power source for melting of frozen pipes!
Remember general fire safety!
Pay attention to the fire safety regulations. Welding is always classified as a fire risk operation.
Welding where there is flammable or explosive material is strictly forbidden.
If it is essential to weld in such an area remove inflammable material from the immediate vicinity of the
welding site.
Fire extinguishers must always be on site where welding is taking place.
Note! Sparks may cause fire many hours after completion of welding.
Watch out for the mains voltage!
Take care of the cables - the connection cable must not be compressed, touch sharp edges or hot work pieces.
Faulty cables are always a fire risk and highly dangerous.
Do not locate the welding machine on wet surfaces.
Do not take the welding machine inside the work piece (i.E. In containers, cars etc.)
Ensure that neither you nor gas bottles or electrical equipment are in contact with live wires or connections!
Do not use faulty welding cables.
Isolate yourself by using dry and not worn out protective clothes.
Do not weld on wet ground.
Do not place the TIG torch or the welding cables on the power source or other electrical equipment.
Be careful of TIG ignition pulse voltage!
Dont press on torch switch, if the torch is not directed towards work piece.
Dont use wet TIG torch. Do not use damaged TIG torch.
Watch out for the welding fumes!
Ensure that there is sufficient ventilation.
Follow special safety precautions when you weld metals which contain lead, cadmium, zinc, mercury or
beryllium.
Note the danger caused by special welding jobs!
Watch out for the fire and explosion danger when welding container type work pieces.
English
TERMS OF GUARANTEE
KEMPPI OY provides a guarantee for products manufactured and sold by them if defects in manufacture and
materials occur. Guarantee repairs must be carried out only an Authorized KEMPPI Service Agent. Packing,
freight and insurance costs to be paid by third party. The guarantee is effected on the day of purchase. Verbal
promises which do not comply with the terms of guarantee are not binding on guarantor
Limitations on guarantee
The following conditions are not covered under terms of guarantee: defects due to fair wear and tear, noncompliance with operating and maintenance instructions, connection to incorrect or faulty supply voltage (including voltage surges outside equipment spec.), incorrect gas pressure, overloading, transport or storage damage, fire or damage due to natural causes i.e. ligthning or flooding.
This guarantee does not cover direct or indirect travelling costs, daily allowances or accomodation.
Note: Under the terms of the guarantee, Welding torches and their consumables, feed, drive rollers and feeder
guide tubes are not covered.
Direct or indirect damage due to a defective product is not covered under the guarantee.
The guarantee is void if changes are made to the product without approval of the manufacturer, or if repairs are
carried out using non-approved spare parts. The guarantee is also void if repairs are carried out by non-authorised agents.
Guarantee period
The guarantee is valid for one year from date of purchase, provided that the machine is used for single-shift
operation. The guarantee period for double and treble shift operation is six months and four months respectively.
Undertaking guarantee repairs
Guarantee defects must be informed to KEMPPI or authorised KEMPPI Service Agents within the guarantee
period. Before any guarantee work is undertaken, the customer must provide proof of purchase and serial
number of the equipment in order to validate the guarantee. The parts replaced under the terms of the guarantee
remain the property of KEMPPI. Following the guarantee repair, the guarantee of the machine or equipment,
repaired or replaced, will be continued to the end of the original guarantee period.
9901 / 1916110E / 3
1. GENERAL
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, 160 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.
ACDC panel
TTM 25W
ACDC minilog ACDC pulse
TTM 15
English
C 100AC
Equipment
Mastertig AC/DC 1600 ............................... 6161600
Mastertig AC/DC 2500 ............................... 6162500
Mastertig AC/DC 2500W ........................... 6162505
Mastertig AC/DC 3500W ........................... 6163505
ACDC panel................................................. 6162801
ACDC minilog .............................................. 6162802
ACDC pulse ................................................. 6162803
Accessories
T 120 transport unit .................................... 6185252
T 22 transport unit ...................................... 6185256
GH 20 (gun holder) ...................................... 6256020
TTM 22
GH 20
C 100F
TIG torches, gas-cooled
TTM 13 .......... 4 m .................................... 6271421
TTM 13 .......... 8 m .................................... 6271422
TTM 15 .......... 4 m .................................... 6271424
TTM 15 .......... 8 m .................................... 6271425
TTM 15 .......... 16 m .................................... 6271428
TTM 15S ....... 4 m .................................... 6271434
TTM 15S ....... 8 m .................................... 6271435
TTM 22 .......... 4 m .................................... 6271426
TTM 22 .......... 8 m .................................... 6271427
TTM 22 .......... 16 m .................................... 6271429
TTM 22S ....... 4 m .................................... 6271436
TTM 22S ....... 8 m .................................... 6271437
Remote control units
C 100C ........................................................ 6185410
C 100D ........................................................ 6185413
C 100AC ...................................................... 6185417
C 100F......................................................... 6185405
Cables
Extension cable for remote control ... 10 m ..... 6185456
Start extension cable C 100F......... 10 m ..... 6185310
Welding cables
Cable for MMA welding .. 25 mm
......................................25 mm
Cable for MMA welding .. 50 mm
......................................50 mm
Return current cable ....... 25 mm
......................................25 mm
Return current cable ....... 50 mm
......................................50 mm
4 / 1916110E / 9901
2
.. 5 m ..... 6184201
2
.. 10 m..... 6184202
2
5 m..... 6184501
..
2
.. 10 m..... 6184502
2
.. 5 m ..... 6184211
2
10 m..... 6184212
..
2
.. 5 m ..... 6184511
2
.. 10 m..... 6184512
TIG torches, water-cooled
TTM 20W ...... 4 m .................................... 6271511
TTM 20W ...... 8 m .................................... 6271512
TTM 25W ...... 4 m .................................... 6271521
TTM 25W ...... 8 m .................................... 6271522
TTM 25WS .... 4 m .................................... 6271531
TTM 25WS .... 8 m .................................... 6271532
TTM 35W ...... 4 m .................................... 6271541
TTM 35W ...... 8 m .................................... 6271542
= Warning
2. INSTALLATION OF THE MACHINE
2.1 Cabling the machine
Mastertig AC/DC 1600
Shielding gas hose
Gas-cooled TIG torch
Cable for MMA welding
Return current cable
Remote control unit
English
Mains cable
Mastertig AC/DC 2500
Shielding gas hose
Cable for MMA welding
Remote control unit
Gas-cooled TIG torch
Return current cable
Mains cable
9901 / 1916110E / 5
Mastertig AC/DC 2500W
English
Shielding gas hose
Cable for MMA welding
Remote control unit
Return current cable
Water-cooled TIG torch
Mastertig AC/DC 3500W
Cable for MMA welding
Remote control unit
Return current cable
Shielding gas hose
Water-cooled TIG torch
6 / 1916110E / 9901
2.2 Siting the machine
When siting the machine, the following have to be
considered:
Site the machine on a fixed 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 the free circulation of the cooling air. Make
sure that there is at least a 20cm free distance
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
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 1600
1600
The Machine is delivered with a mains cable with a
schuko 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 .
English
Mastertig AC/DC 2500 and -2500W: Check first that the
mains voltage change-over switch is in right position.
If it is needed to change mains cable, do it before
mounting to the wheel barrow T120. Otherwise you
bossibly 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.
Mastertig AC/DC 2500, -2500W and -3500W
2500, 2500W, 3500W
The machine is delivered with a 5m mains cable
(4×2.5mm2) without a plug. Mains cable is suitable
for all mains voltages with recommended fuse size
(please look at Technical data table). 4×6mm2 cable
can be assembled 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 / 460V).
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 clight. 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 .
9901 / 1916110E / 7
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