Kemppi Mastercool 12 User Manual
Operation instructions • english
Gebrauchsanweisung • deutsch
Gebruiksaanwijzing • nederlands
Manuel d’utilisation • français
1910030E
0311
2 – Master(tig) 2500, 2503, 3500, 3503 MLS™/ 0311
© COPYRIGHT KEMPPI OY
Master(tig) 2500, 2503, 3500, 3503 MLS™/ 0311 – 3
© COPYRIGHT KEMPPI OY
CONTENTS
1. PREFACE........................................................................................................................ 3
1.1. Introduction ............................................................................................................................... 3
1.2. Product introduction.................................................................................................................. 3
1.3. Operation safety .......................................................................................................................3
2. INSTALLATION ...............................................................................................................4
2.1. Removal from packaging ..........................................................................................................4
2.2. Locating the machine................................................................................................................ 4
2.3. Serial number ...........................................................................................................................4
2.4. Installation and main parts........................................................................................................ 4
2.5. Installation of the panel............................................................................................................. 5
2.6. Mains connection...................................................................................................................... 5
2.7. Welding cable connections ....................................................................................................... 6
2.7.1. Choosing welding polarity in MMA welding .............................................................................. 6
2.7.2. Earthing .................................................................................................................................... 6
2.8. Cooling unit (Mastercool 10, Mastercool 12) ............................................................................6
2.9. Shield gas .................................................................................................................................7
2.9.1. Installation of gas bottle............................................................................................................ 7
3. OPERATION.................................................................................................................... 8
3.1. Welding processes....................................................................................................................8
3.1.1. MMA welding ............................................................................................................................ 8
3.1.2. TIG welding .............................................................................................................................. 8
3.1.3. Synergetic Pulsed TIG welding ................................................................................................ 8
3.1.4. Long Pulsed TIG welding ........................................................................................................ 8
3.2. Operation functions................................................................................................................... 8
3.2.1. Power source............................................................................................................................ 8
3.2.2. Function panels (MTL,MTX, MTZ, MTM, MEL, MEX) .............................................................8
3.2.2.1. Indicator lights .................................................................................................... 9
3.2.2.2. MMA welding panel MEL.................................................................................... 9
3.2.2.3. MMA welding panel MEX ................................................................................. 10
3.2.2.4. TIG welding panel MTL .................................................................................... 11
3.2.2.5. TIG welding panel MTX.................................................................................... 13
3.2.2.6. TIG welding panel MTZ ................................................................................... 14
3.2.2.7. TIG welding panel MTM ................................................................................... 15
3.2.3. Saving welding settings (MTM) .............................................................................................. 16
3.2.4. Adopting the saved settings.................................................................................................. 16
3.2.5. Remote control memory channels.......................................................................................... 16
3.2.6. SETUP functions .................................................................................................................... 16
3.2.7. Foot pedal control R11F ......................................................................................................... 17
3.3. Cooling unit operation (Mastercool 10, Mastercool 12) ..........................................................17
3.4. Storage ................................................................................................................................... 17
4. MAINTENANCE ............................................................................................................18
4.1. Regular maintenance.............................................................................................................. 18
4.1.1. Every sixth months ................................................................................................................. 18
4.1.2. Service contract...................................................................................................................... 18
4.2. Troubleshooting ...................................................................................................................... 18
4.3. Disposal of the machine .........................................................................................................19
5. ORDERING NUMBERS ................................................................................................19
6. TECHNICAL DATA........................................................................................................ 21
Master(tig) 2500, 2503, 3500, 3503 MLS™/ 0311 – 3
© COPYRIGHT KEMPPI OY
1. PREFACE
1.1. INTRODUCTION
Congratulations on having purchased a KEMPPI product. Properly installed and used Kemppi products should prove to be productive machines requiring a small amount of regular maintenance. This
manual is to give you a good understanding of the equipment and its safe operation. It also contains
maintenance information and technical specications. Read this manual completely 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 specications 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 warnings 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
Kemppi Master 2500, 2503, 3500 and 3503 MLS™ is a MMA welding machine designed for industrial use and for welding all kinds of covered electrodes, including difcult-to-weld types such as
cellulose electrodes. The equipment consists of power source, welding cables and function panel.
Kemppi Mastertig 2500, 2503, 3500 and 3503 MLS™ is a TIG welding system especially designed
for industrial use and for welding e.g. stainless steel materials. The equipment consists of a power
source, function panel, TIG welding torch, ground cable and an optional cooling unit. The cooling unit
(Mastercool 10, Mastercool 12) is used in water-cooled TIG welding.
The power source is a multifunctional machine for demanding professional use for MMA, TIG and
pulsed TIG welding with direct current. The power source is controlled with IGBT transistors with a
frequency of approximately 20 kHz, and the operational functions with a microprocessor. The welding
torch can be either water-cooled or gas-cooled.
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 reecting 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 have sufcient re-ghting equipment wherever you are welding. Be prepared for hazards in
special welding jobs, e.g. for 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 (e.g. 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 start a re. Connection cable must not
be crushed, it must not touch sharp edges or hot work pieces.
4 – Master(tig) 2500, 2503, 3500, 3503 MLS™/ 0311
© COPYRIGHT KEMPPI OY
Master(tig) 2500, 2503, 3500, 3503 MLS™/ 0311 – 5
© COPYRIGHT KEMPPI OY
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Welding power circuit
Isolate yourself by using proper protective clothing, do not wear wet clothing. Never work on a
wet surface or use damaged cables. Do not put TIG torch or welding cables on welding machine
or on other electric equipment. Do not press TIG torch switch if the torch is not directed towards
the work piece.
Welding fumes
Take care that there is sufcient ventilation during welding. Take special safety precautions
when welding metals which contain lead, cadmium, zinc, mercury or beryllium.
Lifting the equipment
Always remove gas bottle before lifting.
2. INSTALLATION
2.1. 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.
2.2. 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.
2.3. 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 specic product. It is important to make correct reference to the
serial number of the product when making repairs or ordering spare parts.
2.4. INSTALLATION AND MAIN PARTS
Front of machine
1. Function panel
2. Remote control connector
3. TIG torch control connector, not in MMA version
4. Shield gas and current connector for TIG torch, not in MMA
version
5. (+) connector for electrode holder or earth cable, in TIG welding for earth cable
6. (-) connector for earth cable or electrode holder in MMA
welding (stick welding)
Markings for (+/-) poles on the machine front are embossed.
© COPYRIGHT KEMPPI OY
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Master(tig) 2500, 2503, 3500, 3503 MLS™/ 0311 – 5
Rear of machine
1. Mains switch
2. Snap connector for gas
Torch Installing gas-cooled
torch
Installing water-cooled torch
2.5. 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.
2.6. MAINS CONNECTION
Only an authorised electrician is allowed to install mains cable and plug!
The power source is equipped with a 5-meter mains cable without plug. The plug may be installed by an authorised electrician only. The fuse and cable sizes are given in the Technical data at
the end of this manual.
6 – Master(tig) 2500, 2503, 3500, 3503 MLS™/ 0311
© COPYRIGHT KEMPPI OY
Master(tig) 2500, 2503, 3500, 3503 MLS™/ 0311 – 7
© COPYRIGHT KEMPPI OY
2.7. WELDING CABLE CONNECTIONS
2.7.1. Choosing welding polarity in MMA welding
You can change the welding polarity by choosing (+) or (-) cable connector.
2.7.2. 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 rmly.
2.8. COOLING UNIT (MASTERCOOL 10, MASTERCOOL 12)
Cooling liquid is injurious! Avoid also contact with skin or eyes. In case of injury,
seek for medical advice.
Cooling unit Mastercool 10 and Mastercool 12 together with TIG torch of Kemppi’s 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 10: Mastercool 12:
Mastertig 2500 MLS™ Mastertig 2503 MLS™
Mastertig 3500 MLS™ Mastertig 3503 MLS™
Installation of cooling unit
Master(tig) 2500, 2503, 3500, 3503 MLS™/ 0311 – 7
© COPYRIGHT KEMPPI OY
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2.9. SHIELD GAS
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 ow regulator is suitable for the gas type used. The ow rate is set
according to the welding current, joint form and the size of the electrode. A suitable ow rate
is normally 8 – 10 l/min. If the gas ow is not suitable the welded joint will be porous. Spark
ignition becomes more difcult if the gas ow is too high. Contact your local Kemppi dealer for
choosing gas and equipment.
2.9.1. Installation of gas bottle
Parts of gas ow regulator
A Gas bottle valve
B Pressure regulation screw
C Connecting nut
D Hose spindle
E Jacket nut
F Gas bottle pressure meter
G Gas hose pressure meter
Always fasten gas bottle properly in vertical position in a special holder on the wall or on a
carriage. Remember to close gas bottle valve after having nished welding.
The following installation instructions are valid for most gas ow regulator types:
1. Step aside and open the bottle valve (A) for a while to blow out possible impurities
from the bottle valve. Note! Watch out for the gas ow.
2. Turn 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 regulator 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 lled when the
bottle pressure is 2 bar.
8. Open needle valve if there is one in the regulator.
9. Turn regulation screw (B) until hose pressure meter (G) shows the required ow (or
pressure). When regulating ow amount, the power source should be switched on and
the gun switch pressed simultaneously.
Close bottle valve after having nished welding. If the machine will be out of use for a long
time, unscrew the pressure regulation screw.
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