Kemppi MLS 1600 User Manual

Operation instructions • english Gebrauchsanweisung • deutsch Gebruiksaanwijzing • nederlands Manuel d’utilisation • français

1913160E

0530

MASTER

MLS™ 1600

MASTERTIG

MLS™ 2000

2 – MASTER MLS™ 1600, MASTERTIG MLS™ 2000 / 0530

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. SHIELD GAS ............................................................................................................... 6

2.8.1. INSTALLING GAS BOTTLE ........................................................................... 7

3. OPERATION .................................................................................................................. 7

3.1. WELDING PROCESSES ............................................................................................ 7

3.1.1. MMA WELDING ............................................................................................. 7

3.1.2. TIG WELDING ................................................................................................ 7

3.1.3. SYNERGIC PULSED TIG WELDING ............................................................ 7

3.1.4. LONG PULSED TIG ...................................................................................... 7

3.2. OPERATION FUNCTIONS .......................................................................................... 8

3.2.1. POWER SOURCE ......................................................................................... 8

3.2.2. FUNCTION PANELS ...................................................................................... 8

3.2.3. SAVING WELDING SETTINGS (MTM) ........................................................ 13

3.2.4. TAKING THE SAVED SETTINGS INTO USE .............................................. 14

3.2.5. REMOTE CONTROLLING MEMORY CHANNELS ..................................... 14

3.2.6. SET-UP FUNCTIONS .................................................................................. 14

3.3. STORAGE ................................................................................................................. 14

4. MAINTENANCE ........................................................................................................... 15

4.1. MAINTENANCE ........................................................................................................ 15

4.1.1. EVERY SIXTH MONTHS ............................................................................. 15

4.1.2. SERVICE CONTRACT ................................................................................. 15

4.2. ORDERING NUMBERS ............................................................................................ 15

4.3. TROUBLESHOOTING .............................................................................................. 16

4.4. DISPOSAL OF THE MACHINE ................................................................................. 16

5. TECHNICAL DATA ...................................................................................................... 17

6. TERMS OF GUARANTEE ........................................................................................... 18

MASTER MLS™ 1600, MASTERTIG MLS™ 2000 / 0530 – 3

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 a mount of seasonal maintenance. This manual is arranged to give you a good understanding of the equipment and its safe operation. It also contains maintenance information and technical speciﬁcations. Read this manual completely from front to back before installing, operating or maintaining the equipment for the ﬁrst time. For further information on Kemppi products please contact us or your nearest Kemppi distributor.

The speciﬁcations and designs presented in this manual are subject to change without prior notice.

In this document, where ever there exists a 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 MLS™ 1600 is a MMA welding machine designed for industrial use and for welding all kinds of covered electrodes including difﬁcult-to-weld types such as cellulose electrodes. The equipment consists of power source, welding cables and function panel.

Kemppi MASTERTIG MLS™ 2000 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, panel and TIG-welding torch.

The power source is a multifunctional machine for demanding professional use, suitable for MMA, TIG and pulsed TIG welding with direct current. The power source is controlled with IGBT-transistors with a frequency of approximately 60 kHz and the operational functions with a microprocessor. The welding torch is 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

The welding arc hurts unprotected eyes. Be careful also with reﬂecting arc ﬂash. Welding arc and spatter burn unprotected skin. Use safety gloves and protective clothing.

Danger for ﬁre or explosion

Pay attention to ﬁre safety regulations. Remove ﬂammable or explosive materials from welding place. Always have sufﬁcient ﬁre-ﬁghting equipment where ever you are welding. Be prepared for hazards in special welding jobs, eg. for the danger of ﬁre or explosion when welding container type work pieces. Note! Fire can break out from sparks even several hours after the welding work has been ﬁnished!

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 ﬁre. Connection cable must not be crushed, it must not touch sharp edges or hot work pieces.

4 – MASTER MLS™ 1600, MASTERTIG MLS™ 2000 / 0530

Front of machine

1. remote control connector

2. TIG torch control connector, not in MMAversion

3. shield gas & current connector for TIGtorch, not in MMA-version

4. (+) -connector for electrode holder or earth cable, in TIG-welding for earth cable

5. (-)-connector for earth cable or electrode holder in MMA-welding (stick welding)

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 sufﬁcient 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 specially designed for them. It is however necessary to check the equipment before installing it, to make sure that the equipment or a part of it was not damaged during the transportation. Also check that the delivery corresponds your order and that you have received all the necessary instructions for installing and operating the equipment. The packaging material can be recycled.

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

The serial number of the machine is marked on the rating plate. Identifying the serial number is the only proper means of maintaining and identifying parts for a speciﬁc 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

MASTER MLS™ 1600, MASTERTIG MLS™ 2000 / 0530 – 5

Rear of machine

1. Mains switch

2. Snap connector for gas

2.5. INSTALLATION OF THE PANEL

1. Fasten the cable connectors of the 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 authorized electrician is allowed to install mains cable!

The power source is equipped with a 3 m mains cable with an earthed plug. The plug can be changed only by an authorized electrician. The fuse and cable sizes are given in the chapter Technical data in the end of this document.

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.

Torch Installing torch cable

1. 2.

6 – MASTER MLS™ 1600, MASTERTIG MLS™ 2000 / 0530

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 earth cable directly on work piece.

1. Clean contact surface from paint and rust.

2. Fasten clamp properly, so that contact surface is as large as possible.

3. Check that clamp is fastened ﬁrmly.

2.8. SHIELD GAS

Handle gas bottle with care. There is a risk for injury if gas bottle or bottle valve is damaged!

Use as shield gas argon or other gas suitable for TIG welding.The ﬂow rate of the gas is deﬁned by the welding current and the size of the electrode. If the gas ﬂow is not suitable it might be difﬁcult to weld. Contact your local Kemppi-dealer for choosing gas and equipment.

Parts of gas ﬂow 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

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