Kemppi MLS 2500 User Manual

Master

MLs™ 2500, 2503, 3500, 3503

Mastertig

MLs™ 3000, 3003, 4000, 4003

MastercooL

1910031E

0649

2 – Master MLs™ 2500, 2503, 3500, 3503, Mastertig MLs™ 3000, 3003, 4000, 4003 / 0649 © keMppi oy

CONTENTS

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

1.1. INTRODUCTION ....................................................................................................................

1.2. PRODUCT INTRODUCTION .................................................................................................3

1.3. SAFE OPERATION ................................................................................................................3

2. INSTALLATION .........................................................................................................................4

2.1. REMOVAL FROM PACKAGING .............................................................................................

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 TO MASTERCOOL 10 .................................................................................6

2.9. SHIELD GAS ..........................................................................................................................7

2.9.1. INSTALLATION OF GAS BOTTLE ............................................................................7

3. OPERATION .............................................................................................................................8

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

3.1.1. MMA WELDING ........................................................................................................8

3.1.2. TIG WELDING ...........................................................................................................8

3.1.3. SYNERGETIC PULSED TIG WELDING (A) .............................................................8

3.1.4. LONG PULSED TIG WELDING (B) ..........................................................................8

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

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

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

3.2.3. SAVING WELDING SETTINGS (MTM) ...................................................................15

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 ...............................................................17

3.4. STORAGE ............................................................................................................................17

4. MAINTENANCE ......................................................................................................................

4.1. REGULAR MAINTENANCE .................................................................................................

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 ..........................................................................................................

6. TECHNICAL DATA .................................................................................................................

7. TERMS OF GUARANTEE ......................................................................................................

Master MLs™ 2500, 2503, 3500, 3503, Mastertig MLs™ 3000, 3003, 4000, 4003 / 0649– 3© 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 specications. 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 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 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™ 2500, 2503, 3500 and 3503 is a MMA welding machine designed for industrial use and for welding all kinds of covered electrodes, including difcult-to-weld types such as cellulose electrodes. The equipment consists of power source, welding cables and function

panel.

Kemppi Mastertig MLS™ 3000, 3003, 4000 and 4003 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 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. SAFE OPERATION

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 have sufcient 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 MLs™ 2500, 2503, 3500, 3503, Mastertig MLs™ 3000, 3003, 4000, 4003 / 0649 © keMppi oy

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 sufcient 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 specic 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.

Master MLs™ 2500, 2503, 3500, 3503, Mastertig MLs™ 3000, 3003, 4000, 4003 / 0649– 5© keMppi oy

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 xing 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 xing 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.

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.

6 – Master MLs™ 2500, 2503, 3500, 3503, Mastertig MLs™ 3000, 3003, 4000, 4003 / 0649 © 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 TO MASTERCOOL 10

Cooling liquid is injurious! Avoid also contact with skin or eyes. In case of injury, seek for medical advice.

Cooling unit Mastercool 10 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 etanol and water, or with any other suitable antifreeze. The capacity of the reservoir is 3 litres.

Mastercool 10:

Mastertig MLS™ 3000 Mastertig MLS™ 4000

Mastertig MLS™ 3003 Mastertig MLS™ 4003

Installation of cooling unit

Master MLs™ 2500, 2503, 3500, 3503, Mastertig MLs™ 3000, 3003, 4000, 4003 / 0649– 7© keMppi oy

E D

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 difcult 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.

(a)

(b)

3. OPERATION

Welding in places presenting an immediate re or explosion hazard is forbidden!

Welding fumes may cause injury, take care of sufcient ventilation during welding!

3.1. WELDING PROCESSES

3.1.1. MMA welding

MMA welding, as well as carbon arc gouging, is possible with all Master MLS™ and Mastertig MLS™ power sources with all MLS panel versions when switched to MMA process.

3.1.2. TIG welding

Mastertig MLS™ power sources are designed especially for TIG welding. They are equipped with HF spark ignition and versatile panel functions depending on the panel used. The panels predominantly for TIG welding are MTL, MTX, MTZ and MTM. Also the MEL and MEX panel on Master MLS™ power source can be used for TIG welding with contact ignition.

3.1.3. Synergetic Pulsed TIG welding (a)

MTX, MTZ and MTM panels include the synergetic pulsed TIG process, in which you only need to adjust the welding current while other pulse parameters are programmed. Pulsing frequency is high, which guarantees concentrated arc and increased welding speed.

3.1.4. Long Pulsed TIG welding (b)

This method gives you the possibility to adjust all pulse parameters. Weld pool control is also easier. Long pulsed TIG welding is included in MTX, MTZ and MTM panels.

3.2. OPERATION FUNCTIONS

3.2.1. Power source

Always switch the machine on and off from main switch. Do not use the mains plug for switching!

Never watch the arc without a proper face shield designed for arc welding! Protect yourself and the surroundings against welding arc and hot spatters!

3.2.2. Function panels

Before welding starts, welding settings suitable for the work piece are chosen with the function

panel. See 3.1. Welding processes.

The Kemppi Multi Logic System, MLS™, allows you to select from different function panels according to your welding application. MEL and MEX panels are designed for MMA welding. MTL, MTX, MTZ and MTM panels are for TIG welding with basic functions, or with pulsed TIG, 4T-LOG, or MINILOG control of welding current, or with memory channels. See also 3.1.

Welding processes.

1 2 3

3.2.2.1. Indicator lights

1. Power On

2. Thermal overload of power source

3. Wrong mains voltage, over or under-voltage

3.2.2.2. MMA welding panel MEL

1. Remote/local control switch

2. Welding current potentiometer

3. Contact TIG welding

4. MMA welding

5. Arc force

6. Hot start

7. Digital display and amperage/voltage switch

8. Welding current table

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