Mastertig MLS™ 2300 ACDC, Mastercool 20
Contents
1. KEMPPI UK Ltd Martti Kemppi Building Fraser Road Priory Business Park BEDFORD MK44 3WH UNITED KINGDOM Tel 44 0 845 6444201 Telefax 44 0 845 6444202 sales uk kemppi com KEMPPI FRANCE S A S 65 Avenue de la Couronne des Pr s 78681 EPONE CEDEX FRANCE Tel 33 1309004 40 Telefax 33 1 3090 04 45 sales fr kemppi com KEMPPI GmbH Otto Hahn StraBe 14 D 35510 BUTZBACH DEUTSCHLAND Tel 49 6033 88 020 Telefax 49 6033 72 528 sales de kemppi com KEMPPI SP KA Z 0 0 Ul Borzymowska 32 03 565 WARSZAWA POLAND Tel 48 22 7816162 Telefax 48 22 7816505 info pl kemppi com KEMPPI AUSTRALIA PTY LTD 13 Cullen Place PU Box 5256 Greystanes NSW 2145 SMITHFIELD NSW 2164 AUSTRALIA Tel 61 2 9605 9500 Telefax 61 2 9605 5999 info au kemppi com 000 KEMPPI Polkovaya str 1 Building 6 127018 MOSCOW RUSSIA Tel 7 495 739 4304 Telefax 7 495 739 4305 info ru kemppi com 000 KEMITIIM yn lonkoBaa 1 crpoeHue 6 127018 MockBa Tel 7 495 739 4304 Telefax 7 495 739 4305 info ru kemppi com KEMPPI TRADING BEIJING COMPANY LIMITED Room 420 3 Zone Building B No 12 Hongda North Street Beijing Economic Development Zone 100176 Beijing CHINA Tel 86 10 6787 6064 86 10 6787 1282 Telefax 86 10 6787 5259 sales cn kemppi com BAD IR ARAA BLA TRA ZE ZR ERR 12 5 fil Bt KBR X420 100176 FIG 86 10 6787 6064 86 10 6787 1282 f B 86 10 6787 5259 sales cn kemppi com KEMPPI IN2. 180 A 27 2V 32V 180 A MMA 6 1 5 4 0 mm 58V stepless 82 180 27 2V 78 230 19 2V 0 99 6W 180W 430 x 180 x 390 mm 650 mm power source cooling unit 15 kg 230V 15 15 96 50W 1 0 kW 4 0 bar glycol water approx 3 500 x 180 x 260 mm 8kg 21 MasterTig MLS 2300 ACDC Kemppi Oy 1112 EN MasterTig MLS 2300 ACDC Kemppi Oy 1112 EN 22 Power source and cooling unit Operating temperature range Storage temperature range EMC class Degree of protection Recommended generator Smin 8 kVA 20 C 40 C 20 C 60 C A IP 23 C ZLLL AO ddwy DADY 00 amp c SIN BILISISEW EN 23 KEMPPI OY Hennalankatu 39 PL 13 FIN 15801 LAHTI FINLAND Tel 358 3 899 11 Telefax 358 3 899 428 export kemppi com www kemppi com Kotimaan myynti Tel 358 3 899 11 Telefax 358 3 734 8398 myynti fi kemppi com KEMPPI SVERIGE AB Box 717 5 194 27 UPPLANDS V SBY SVERIGE Tel 46 8 590 783 00 Telefax 46 8 590 823 94 sales se kemppi com KEMPPI NORGE A S Postboks 2151 Postterminalen N 3103 TONSBERG NORGE Tel 47 33 346000 Telefax 47 33 346010 sales no kemppi com KEMPPI DANMARK AS Literbuen 11 DK 2740 SKOVLUNDE DANMARK Tel 45 4494 1677 Telefax 45 4494 1536 sales dk kemppi com KEMPPI BENELUX B V Postbus 5603 NL 4801 EA BREDA NEDERLAND Tel 31 765717750 Telefax 31 765716345 sales nl kemppi com www kemppi com
3. KEMPPI The Joy of Welding MasterTig MLS 2300 ACDC Operating manual English K ytt ohje Suomi Bruksanvisning Svenska Bruksanvisning Norsk Brugsanvisning Dansk Gebrauchsanweisung Deutsch Gebruiksaanwijzing Nederlands Manuel d utilisation Francais Manual de instrucciones Espa ol Instrukcja obs ugi Polski VHcrpykunn no skcnnyaTauinu lo pycckn REFA PZ Manual de utiliza o Portugu s Manuale d uso Italiano EN H SV DA DE NL FR ES PL RU ZH PT IT ZLLL AO ddwy DADY 00 amp c SIN D 181selw OPERATING MANUAL English MasterTig MLS 2300 ACDC Kemppi Oy 1112 EN CONTENTS 1 PREFACE GR RS oo o S NA O A irinn 3 1 1 GERE EEN 3 1 2 Product introduction waski dE RE POR ani non 3 2 INSTALLATION 4 2 Removal from packaging aaa GA A OO 4 22 Locating the MACRIR S 2m reine 4 23 Seid Ee il 4 24 installation and main Parts iles 4 2 5 Installation of the panela w a AA o 5 Sketch EYE ann 6 2 7 Distribution hee yk waciki EO md ni 6 28 Welding cable CONN CHONS sms 6 29 Cooling unit to Mastercool 20 seiten suv sri 6 2 10 Eo RS 9 8 3 OPERATION 9 3 1 Welding processes EE stades 9 3 1 1 IMMA welding eebe nal E ER REEL RETRO URS 9 3 1 2 TIG welding Alternating Current 9 3 1 3 TIG Welding with Direct Current en 9 3 1 4 Synergetic Pulsed TIG welding sss 10 3 1 5 Long
4. Pulsed TIG welding ss 10 3 1 6 Spot welding function 10 3 1 7 MicroTack functio Nonnan EA Ea i 10 3 1 8 TIG welding with mixed AC DC current MIX 10 3 2 Operation fl toig necp npa PRO PUT Z REGA GOA 10 322 1 POWETSOUCR S cerent nemi diat anni Qon hi 10 3 22 Function paneler e eda atn iei a Rete 10 3 2 3 Saving welding settings 15 3 24 Adopting the saved settings 16 3 25 Remote control memory channels 16 3 2 6 SETUP f nctionsiiaasiea nado peni E Ee 16 3 27 Foot pedal control R11F 16 3 3 Cooling unit operation Mastercool 20 16 34 SONG d 16 E ET CN 17 3 6 JEROMCOGES EE 18 4 MAINTENANCE 18 4 1 e TEEN 18 42 Troubleshoot serye senhes ro 19 4 3 Disposal of the machine 19 5 ORDERING NUMBERS oosi oni svoonevvv ov 20 6 TECHNICAL DATA iste los a an 21 1 1 1 2 PREFACE GENERAL Congratulations on your choice of the Kemppi MasterTig MLS ACDC welding system Reliable and durable Kemppi products are affordable to maintain and they increase your work productivity This user manual contains important information on the use maintenance and safety of your Kemppi product The technical specifications of the device can be found at the end of the manual Please read the manual carefully before using the equipment for the first time For your safety and that of your working environment pay p
5. of glycol and water or with any other suitable antifreeze The capacity of the reservoir is 3 litres Mastercool 20 Installation of cooling unit Electrical connection for the cooling unit 1 230V 2 Control connector 3 Equipment earth NOTE Only an authorised electrician is allowed to install electrical connection MasterTig MLS 2300 ACDC Kemppi Oy 1112 EN MasterTig MLS 2300 ACDC Kemppi Oy 1112 EN 2 10 2 10 1 SHIELD GAS NOTE 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 flow regulator is suitable for the gas type used The flow rate is set according to the welding current joint form and the size of the electrode A suitable flow rate is normally 8 10 l min If the gas flow is not suitable the welded joint will be porous Spark ignition becomes more difficult if the gas flow is too high Contact your local Kemppi dealer for choosing gas and equipment A C F Parts of gas flow regulator Gas bottle pressure meter Gas hose pressure meter A Gas bottle valve B Pressure regulation screw C Connecting nut D Hose spindle E Jacket nut F G Installation of gas bottle NOTE Always fasten gas bottle properly in vertical position in a special holder on the wall or ona carriage Remember to close gas b
6. oxide break up Application areas include repair welding and casting 2 Frequency FrE 50 250 Hz factory setting 60 Hz Raising the frequency will make the arc slightly more stable and narrow but it will increase the noise caused by arc 3 Selection of AC waveform sine or square wave SinuS SquArE The waveform affects the noise level and penetration of the arc A sine waveform generates a lower noise level while a square wave has better penetration factory setting 4 Hot Start time for the 2T function H2t 0 1 s 5 0 s factory setting 1 s Pre heating timer for the 2T switch function The workpiece can be pre heated Hot Start with both AC and DC currents The time set here remains in effect for DC TIG current types 3 MIX TIG mixed current AC DC With mixed current frequency and balance of alternating current are determined by adjustments made for AC current Adjust by choosing sections 4 5 if needed The following QUICK SETUP parameters can be adjusted AC time AC 10 90 factory setting 50 Cycle time CYc 0 1 1 0 s factory setting 0 6 s DC current DC 50 150 96 factory setting 100 Balance bAL 50 0 10 96 factory setting 25 96 Frequency FrE 50 250 Hz factory setting 60 Hz Selection of AC waveform sine or square wave SinuS SquArE Hot Start time for the 2T function H2t 0 1 s 5 0s factory setting 1 0 s Can be seen only on the 2T function Factory settin
7. the value on the numerical display After 10 seconds the display will return to the welding current 13 MasterTig MLS 2300 ACDC Kemppi Oy 1112 EN MasterTig MLS 2300 ACDC Kemppi Oy 1112 EN 14 Welding panel ACX pulsed TIG and MINILOG function with memory XO oo NI OY UY dm WAD 14 SPOT ay Bc SYNERGIC 4T LOG and MINILOG function selections Search arc 5 90 96 of welding current Start current 80 150 96 Minilog current 10 150 96 of welding current Tail arc 5 90 96 of welding current Selection for spot synergetic quick pulse and long pulse Spot time 0 0 10 0 s Pulse current 10 A power source max Pulse ratio 10 70 96 of pulse time Frequency 0 2 250 Hz DC TIG 0 2 20 Hz AC TIG Base current 10 70 96 of pulse current MEMORY memory function Selection of channel in memory function SAVE memory values If wanted in SETUP function you can disable search arc and tail arc functions Hot Start Soft Start and Minilog currents can be disabled by adjusting the values to 100 per cent the same as the welding current 3 2 3 Minilog When torch switch is pressed gas flow starts When you release the torch switch current goes through upslope to Hot Start or Soft Start current depending on adjustments and by pressing shortly again to welding current After another short press it goes to Minilog operation and you can select from two current levels th
8. 220 4m TTC220 8m TTC220 16m Gas flow meter AR clock Cooling unit Mastercool 20 Water cooled torches TTC 200W 4m TTC 200W 8m TTC200W 16m TTC250W 4m TTC250W 8m TTC250W 16m Optional device TIG torch controls RTC 10 RTC 20 Remote control R10 R11F Transport unit T130 T110 6162300 6162805 6162804 6184103 6184201 6184202 6184301 6184113 6184211 6184212 6184311 627016004 627016008 627016016 627022004 627022008 627022016 6265136 6162900 627020504 627020508 627020516 627025504 627025508 627025516 6185477 6185478 6185409 6185407 6185222 6185251 TECHNICAL DATA Power source Mastertig MLS 2300 ACDC Connection voltage Rated power 40 ED TIG 230A 60 ED TIG 200A 100 ED TIG 170A 40 ED MMA 180A 6096 ED MMA 150A 10096 ED MMA 120A Connection cable HO7RN F Fuse delayed Welding current range TIG MMA Max welding voltage Electrode sizes to be welded Open circuit voltage max Welding current adjustment Efficiency at nominal values Power factor at nominal values Open circuit power TIG MMA External dimensions LxWxH height Weight Cooling unit TIG welding Mastercool 20 Connection voltage Connection capacity 100 ED Cooling power Start pressure max Cooling liquid 20 40 Reservoir volume External dimensions LxWxH Weight 1 230V 15 15 5 7 kVA 4 8 kVA 3 9 kVA 6 0 kVA 4 8 kVA 3 7 kVA 362 5 3 3 m 15A 3A 10 0V 230A 19 2V 10 A 20 5 V
9. DIA PVT LTD LAKSHMITOWERS New No 2 770 First Main Road KAZURA Gardens Neelangarai CHENNAI 600 041 TAMIL NADU Tel 91 44 4567 1200 Telefax 91 44 4567 1234 sales india kemppi com TLLL TEOOL6L
10. ailures detected If failures are detected during start up they are shown as error codes on the control panel display Err3 Overvoltage or undervoltage The machine has stopped the welding because it has detected momentary voltage spikes or continuous mains over or under voltage dangerous to the machine Check the quality of the supply network Err4 Power source overheating The power source has overheated The cause may be one of the following The power source has been used for a long time at maximum power The circulation of cooling air to the power source is blocked The cooling system has experienced a failure Remove any obstacle to air circulation and wait until the power source fan has cooled down the machine MAINTENANCE NOTE Watch out for mains voltage when handling electric cables Degree and circumstances of machine utilisation should be taken into consideration when planning product maintenance Careful use and preventive maintenance help to avoid unnecessary production disturbances and breaks Check the condition of the welding and connection cables daily Do not use damaged cables REGULAR MAINTENANCE Every sixth months NOTE Disconnect the plug of the machine from the mains socket and wait for ca 2 minutes capacitor charge before removing the casing plate The following maintenance operations should be carried out at least every sixth months e Electric connections of the machine clean any oxidised part
11. ark ignites the arc and the current will rise to the Hot Start current within the up slope time You can switch from Hot Start current to welding current with a short press of the torch switch You can disable the Hot Start function by adjusting the Hot Start current to zero per cent The current will then rise directly to the welding current level within the up slope time Press the torch switch down and the welding continues Release the torch switch and the current starts to drop and after the selected down slope time the arc is broken After this the shield gas will flow for the time selected Remote control If you choose to adjust the welding current with a remote control unit you need to connect the unit and select the remote control selection button The PANEL light switches off and you can select the unit R10 foot pedal control R11F or torch control The foot pedal control works only in 2T mode Hold the remote control selection button LO HI down to adjust the limits of the remote control s adjustment range Adjustment of parameters To select TIG welding parameters you only need to use two buttons arrow left and arrow right Red panel light shows parameter you have chosen Adjustment is done with the potentiometer When pressing the RETURN button adjustment of parameters goes straight to welding current The display shows automatically numeric values and the units of the parameters When you adjust the parameters you can see
12. articular attention to the safety instructions in the manual For more information on Kemppi products contact Kemppi Oy consult an authorised Kemppi dealer or visit the Kemppi Web site at www kemppi com The specifications presented in this manual are subject to change without prior notice Important notes Items in the manual that require particular attention in order to minimise damage and personal harm are indicated with the VOTE notation Read these sections carefully and follow their instructions Disclaimer While every effort has been made to ensure that the information contained in this guide is accurate and complete no liability can be accepted for any errors or omissions Kemppi reserves the right to change the specification of the product described at any time without prior notice Do not copy record reproduce or transmit the contents of this guide without prior permission from Kemppi PRODUCT INTRODUCTION Kemppi Mastertig MLS ACDC is a family of TIG welding machines designed for industrial use with characteristics especially suitable for welding materials like aluminium and stainless steel The equipment consists of power source function panel and welding torch The cooling unit Mastercool 20 is used in water cooled TIG welding The welding torch can be either water cooled or gas cooled Multipurpose power source Mastertig MLS 2300 ACDC of 230 A maximum current is designed for demanding professional w
13. ble to save the currently used panel parameters by pressing SET SAVE by choosing channel ja by pressing SET SAVE again Channel is cleared if MEMORY and CH buttons are pressed simultaneously in SET mode PWN 15 MasterTig MLS 2300 ACDC Kemppi Oy 1112 EN MasterTig MLS 2300 ACDC Kemppi Oy 1112 EN 3 2 4 3 2 5 3 2 6 3 2 7 3 3 3 4 16 Adopting the saved settings 1 Select MEMORY by pressing the button 2 Select memory channel by pressing the CH button 3 Start welding Remote control memory channels Memory channels are selected by pressing simultaneously both REMOTE and CH button With the remote control you can retrieve saved settings on memory channels 1 5 The selected channel is marked with a dot SETUP functions A so called SETUP state is included for modifying panel functions You can enter the SETUP state by pressing the SETUP button longer than normally Exit is performed in the same way You can select the function see list below by pressing the arrow buttons and then change the setting by turning the potentiometer See SETUP function table on the next page Foot pedal control R11F First read ACS Welding Panel Basic Functions point Remote control for installing the remote control ready for operation Foot pedal R11F is used in TIG welding and its control range is adjustable The minimum value of control range is set with the panel potentiometer when the pedal is not
14. e control connector TIG torch control connector Shieldgasandcurrentconnectorfor TIG torch connectorforelectrode holder connector for earth cable 2 1 Installing gas cooled torch 2 Installing water cooled torch 3 Torch 2 5 INSTALLATION OF THE PANEL Markings for poles on the machine front are embossed Rear of machine 1 Mains switch 2 Snap connector for gas 1 Fasten the cable connectors of the function panel to the power source 2 pieces 2 Placethe bottom edge ofthe 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 MasterTig MLS 2300 ACDC O Kemppi Oy 1112 EN MasterTig MLS 2300 ACDC Kemppi Oy 1112 EN 2 6 2 7 2 8 2 8 1 2 8 2 2 9 MAINS CONNECTION NOTE Only an authorised electrician is allowed to install mains cable and plug The machine comes equipped with a three metre power cord with a Schuko plug Only an authorised electrician is allowed to replace the plug The fuse and cable sizes are given in the Technical data at the end of this manual NOTE This equipment s electromagnetic compatibility EMC is designed for use in an industrial envi
15. e welding current and the Minilog current You can move from one to the other by quickly pressing the torch switch Press the torch switch for one second release it and current goes to downslope and tail arc Arc is cut by short press of the switch 4T LOG When torch switch is pressed current goes to search arc after the switch is released current goes to welding current within the upslope time When the switch is pressed again current goes to downslope and then to the tail arc Current stops when the switch is released Synergetic quick pulse Press the PULSE button twice and the synergetic light turns on Pulse parameters are calculated automatically when average welding current is selected Other pulse selections are not necessary Long pulse Long pulse method gives you the possibility to adjust all pulse parameters pulsing frequency pulse ratio pulse current and pause current You can also adjust the welding current in which case you receive a new pulse current value Pulse ratio and pause current percentage remain constant When you adjust the pulse ratio pulse current or pause current the new average welding current value is shown on the display Spot welding function The function can be used both in 2T and 4T mode Enter the spot duration by pressing arrow button and when the led is lit you can choose the spot time needed by turning the pulse potentiometer TIG Micro tack welding function MicroTack You can select t
16. eeds 25 C 3 5 SETUP FUNCTIONS SETUP function Upslope current dependency C Downslope current dependency C TIG Antifreeze C MMA Antifreeze C VRD C 2T downslope cut off Tacking automatics Limitation of rate of current rise with high currents MMA TIG method selection with remote control C SearchArc On Off Current freeze function Memory channel selection with Up Down buttons C Activation of the Plus Minus buttons Water cooler flow guard C Water cooler automatic control C Water cooler temperature guard C Automatic remote control device recognition C Tail arc Display Al A2 A3 A4 A7 A8 A9 A 0 A12 A13 A4 A15 A 6 A20 A21 A22 ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF C Common applies to all memory channels Factory setting with a grey background The upslope time is determined by the current The upslope time remains as set The downslope time is determined by the current the user may set the slope gradient The downslope time remains as set TIG Antifreeze on TIG Antifreeze off MMA Antifreeze on MMA Antifreeze off VRD mode idle voltage lt 35V Normal idle voltage In 2T mode cut off the downslope with a quick push of the start but
17. elding suitable for electrode TIG and pulsed TIG welding with both direct and alternating current The power source is controlled with IGBT transistors with a frequency of approximately 65 kHz and the operational functions with a microprocessor MasterTig MLS 2300 ACDC Kemppi Oy 1112 EN MasterTig MLS 2300 ACDC Kemppi Oy 1112 EN 2 1 2 2 2 3 2 4 INSTALLATION 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 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 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 specific product It is important to make correct reference to the serial number of the product when making repairs or ordering spare parts INSTALLATION AND MAIN PARTS Front of machine 1 2 3 4 n Function panel Remot
18. fumes may cause injury take care of sufficient ventilation during welding WELDING PROCESSES MMA welding With Mastertig MLS ACDC power sources you can use all electrodes suitable for direct and alternating current welding between current limits of the power source Both function panels ACS ACX can be used for electrode welding when MMA welding is selected TIG welding Alternating Current The Mastertig ACDC MLS power sources are specially designed for TIG welding aluminium with alternating current AC We recommend using WC20 electrodes grey for AC welding The table is only given as a guide Welding current range AC Electrode Gas nozzle Gas flow rate min min maks WC20 Argon VA min T LL A A A 6mm number 6mm 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 The table and the panel scale are based on the use of WC20 grey TIG Welding with Direct Current DC welding is typically used when welding different grades of steel We recommend using WC20 electrodes grey for DC welding A directive electrode selection table for DC welding Welding current range Electrode Gas nozzle Gas flow rate fo DC WC20 Argon H A omm number omm 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 24 6 7 9 5 11 0 7 8 MasterTig MLS 2300 ACDC Kemppi Oy 1112 EN MasterT
19. g is marked with a dot after the numeric value Growing DC current increases penetration but decreases cleaning effect 4 DC or DC direct current No parameters to adjust You can see recommended diameter for elektrode by pressing QUICK SETUP button Diameter depends on current adjustment iiv ur wie HF contact ignition in TIG welding water fill TIG arc can be started either with high frequency HF or without contact ignition HF ignition is chosen by pressing the HF CONTACT button to turn on the HF light If you use water cooled torch you can fill it with water by pressing the HF CONTACT button for more than 2 seconds The display reads COOLER Welding torch switch 2 sequence function Gas flow starts when the torch switch is pressed Welding starts and the current will rise to the Hot Start current within the up slope time remain at that level for the set time H2t and then change to the welding current The Hot Start function can be disabled and green panel light switches off when the Hot Start current is adjusted to 100 96 The current will then rise directly to the welding current level within the up slope time Release the torch switch and the current starts to drop and after the selected down slope time the arc is broken After this the shield gas will flow for the time selected Welding torch switch 4 sequence function Gas flow starts when the torch switch is pressed Release the torch switch The ignition sp
20. he Kemppi Multi Logic System MLS allows you to select the function panel based on the purpose of use the ACS panel for AC TIG welding with basic functions or the ACX panel with pulsed TIG 4T LOG or MINILOG control of welding current and memory channel functions The current display accuracy is 3 96 2 A and the voltage display accuracy is 3 96 0 2 V Indicator lights 1 Power On 2 Thermal overload of power source 3 Wrong mains voltage over or under voltage ACS welding panel basic functions 12 13 14 15 16 KEMPPI 1 Selection button and indicators for TIG welding and current type 2 Selection button and indicators for MMA welding and current type 3 Current and voltage display display for other welding parameters 4 QUICK SETUP button for MMA and TIG adjustments e g balance adjustment 5 Selection of the torch switch function 2T 4T 6 HF contact TIG WATER FILL button 7 Remote control selection button setting the limits for the adjustment range LO HI 8 Welding parameter selection buttons arrow buttons 9 RETURN button returns to welding current 10 GASTEST button 11 Potentiometer for welding parameter adjustment 12 Pre gas 0 0 10 0 s 13 Upslope 0 0 10 0 s 14 Hot Start current 100 150 96 100 96 not in use 15 Welding current 16 Downslope 0 0 15 0 s 17 Post gas 1 0 30 0 s 1 MMA Select MMA welding by pressing the MMA selection button The indicator light
21. he Micro Tack function with a long press of the SPOT arrow button When this function is activated the machine automatically enables the DC welding mode 2T switch mode and contact ignition Also the upslope and downslope values are set to zero and SPOT led starts to blink To inactivate the Micro Tack you press briefly the same arrow button This function can be used with HF ignition and 4T mode The duration of the spot weld can be adjusted by pressing Quick Setup button and selecting a value in the range 1 200 ms The Micro Tack welding current can be adjusted with the control knob when the welding current led is on Saving welding settings ACX panel has 10 memory channels for user settings The selections are made in the MEMORY field Not only welding parameters but also function selections can be saved in the memory MMA welding values can also be stored in memory channels Proceed as follows 1 Press MEMORY button and if the SET light starts blinking the channel is free Ifa channel is in use the ON light will light up Press again and the SET light will be continuously lit Select memory channel by pressing CH button Select the parameters and press SAVE button Press MEMORY button twice ON led is lit 5 Start welding If the saved settings need to be adjusted the led has to be moved from ON to SET position in order to select parameters Press the SAVE button When the memory function is in OFF state no lights on it is also possi
22. ig MLS 2300 ACDC Kemppi Oy 1112 EN 3 1 4 3 1 5 3 1 6 3 1 7 3 1 8 3 2 3 2 1 3 2 2 10 Synergetic Pulsed TIG welding The ACX panel includes the synergetic 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 Long Pulsed TIG welding This method gives you the possibility to adjust all pulse parameters Weld pool control is also easier Long pulsed TIG welding is included in the ACX panel Spot welding function In spot welding function you can to adjust the duration of the welds in the range 0 10 s MicroTack function MicroTack welding is an efficient way to connect thin materials together using low heat input which decreases distortions in base material TIG welding with mixed AC DC current MIX Especially joining materials of different thicknesses can best be made out by using mixed current Adjust values with SETUP function if needed OPERATION FUNCTIONS Power source NOTE Always switch the machine on and off from main switch Do not use the mains plug for switching NOTE Never watch the arc without a proper face shield designed for arc welding Protect yourself and the surroundings against welding arc and hot spatters Function panels Before welding starts welding settings suitable for the work piece are chosen with the function panel T
23. next to the button will light up when MMA is selected The current type indicator light indicates which current is selected AC DC DC Change the current type by pressing the MMA button again and the indicator light will indicate the selected current Press the QUICK SETUP button if you wish to adjust the dynamics or ignition pulse to MMA welding Navigate with the arrow buttons and adjust with the potentiometer Quit by pressing again QUICK SETUP or RETURN button 11 MasterTig MLS 2300 ACDC Kemppi Oy 1112 EN 2 Kemppi Oy 1112 MasterTig MLS 2300 ACDC EN 12 1 Dynamics Arc 9 0 49 You will see the numerical value corresponding to the MMA dynamics in the display Factory setting for all electrode types is zero You can change the value by turning the pulse potentiometer If numerical value is adjusted negative 1 9 the arc is softened and the amount of spatter decreases when welding at the upper end of the recommended current range of the electrode On the positive side 1 9 the arc is rough 2 Ignition pulse Hot 9 0 9 You will see on the display the numerical value corresponding to the MMA hot start pulse You can adjust the value by turning the potentiometer A positive value corresponds to a more powerful pulse with zero being the default setting 2 TIG welding Select TIG welding by pressing the TIG button You can change the current type by pressing the selection bu
24. ottle valve after having finished welding The following installation instructions are valid for most gas flow 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 flow Turn the press regulation screw B of the regulator until no spring pressure can be felt Close needle valve if there is one in the regulator Install the regulator on bottle valve and tighten connecting nut C with a wrench Install hose spindle D and jacket nut E into gas hose and tighten with hose clamp 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 filled when the bottle pressure is 2 bar 8 Open needle valve if there is one in the regulator 9 Turnregulation screw B until hose pressure meter G shows the required flow or pressure When regulating flow amount the power source should be switched on and the gun switch pressed simultaneously Close bottle valve after having finished welding If the machine will be out of use for a long time unscrew the pressure regulation screw Au hwy 3 1 3 1 1 3 1 2 3 1 3 OPERATION NOTE Welding in places presenting an immediate fire or explosion hazard is forbidden NOTE Welding
25. pressed display shows LO Control range maximum is set similarly by pressing first the PEDAL LO HI button on the panel display shows HI Welding is started with a light press on the pedal the arc ignites to the set minimum current Welding current goes to maximum when the pedal is pressed to the bottom The arc is broken when the pedal is released Adjust again if necessary COOLING UNIT OPERATION MASTERCOOL 20 The operation of Mastercool cooling unit is controlled by the power source The cooling unit pump starts automatically when welding starts Proceed as follows 1 Start power source 2 Check water level and input flow of the reservoir add liquid if needed 3 Ifyou use a water cooled torch you can fill it with water by pressing WATER FILL button for more than 2 seconds The pump operates for 4 another minutes after welding has been finished to cool the water to the same temperature as in the machine surrounds This reduces the need of service Thermal overload The thermal overload light is lit the machine stops and display shows COOLER when temperature control of the machine has detected cooling water overheating The cooling unit fan cools down the water and when the light goes out welding can be started again Water flow signal Display shows COOLER when water flow is blocked STORAGE The machine must be stored in a clean and dry room Protect the machine from rain and direct sunshine in places where temperature exc
26. ronment Class A equipment is not intended for use in residential location where the electrical power is provided by the public low voltage supply system DISTRIBUTION NETWORK All regular electrical devices without special circuits generate harmonic currents into distribution network High rates of harmonic current may cause losses and disturbance to some equipment Equipment complying with IEC 61000 3 12 WELDING CABLE CONNECTIONS The welding cables must be made of at least 16 mm copper cable Choosing welding polarity in MMA welding You can select the polarity electronically from the control panel i e you do not have to switch the places of the and connectors Connect always the negative connector to the work piece 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 firmly COOLING UNIT TO MASTERCOOL 20 NOTE Cooling liquid is injurious Avoid also contact with skin or eyes In case of injury seek for medical advice Cooling unit Mastercool 20 together with TIG torch Kemppi 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 96 mixture
27. s and tighten any loose ones NOTE You must know the correct tension torques before you start repairing the connections Clean the inner parts of the machine from dust and dirt e g with a soft brush and a vacuum cleaner Do not use compressed air because there is the danger that the dirt is packed even more tightly in the gaps of the cooling profiles Do not use a pressure washer NOTE Only an authorised electrician may repair the machine Service contract KEMPPI service workshops make special service contracts with customers about regular maintenance All parts are cleaned checked and if necessary repaired Also the operation of welding machine is tested 4 2 4 3 TROUBLESHOOTING Power On light is not lit There is no power in the machine Check mains fuses replace blown fuses Check mains cable and plug replace defect parts The machine is not welding properly There are plenty of spatters during welding Weld joint is porous or power supply is insufficient Check welding settings and adjust if needed Check gas flow and gas hose connection Checkthat earth clamp is properly fastened and that earth cable has no defects Change the position if necessary and replace defect parts Check welding torch cable and connector Tighten the connection and replace defective parts Checkthe consumable parts of welding torch Clean and replace defect parts Check mains fuses replace blown fuses Power source o
28. ton Quick push has no effect If welding has lasted less than 3 seconds no downslope when welding is stopped Tacking automatics off If the current is over 100 A and UpSlope is 0 0 sec there is a 0 2 second slope from half the welding current Current rises directly to maximum TIG the start of remote control scale MMA the end of the scale Remote control as a normal current regulator SearchArc on SearchArc off During the downslope the current can be frozen at a certain level by pushing the start button Freeze function off The Plus Minus buttons on the remote control can be used to select the memory channel The buttons adjust the current The Plus Minus remote control is always active The Plus Minus remote control is active only when selected by pressing the REMOTE button Flow guard on Flow guard off Automatic control on Water cooler runs constantly Water cooler temperature guard selected Temperature guard off Automatic recocnition on control cannot be selected if it is not connected Automatic recocnition On Off Controller can be selected even if it is not connected Tail arc on 4T LOG Tail arc off MINILOG 17 MasterTig MLS 2300 ACDC Kemppi Oy 1112 EN MasterTig MLS 2300 ACDC Kemppi Oy 1112 EN 3 6 4 1 4 1 1 4 1 2 18 ERROR CODES The machine always checks its operation automatically during start up and reports any f
29. tton again AC MIX DC DC Selecting DC requires holding down the button According to selected current mode you can adjust parametres by using QUICK SETUP funktion Quit from QUICK SETUP function by pressing QUICK SETUP button At the same time you can see recommended diameter for elektrode ACTIG alternating current TIG Intended for welding aluminium You can adjust for example the balance and frequency of the alternating current with the QUICK SETUP and arrow buttons The following welding parameters can be adjusted 1 Balance bAL 50 0 factory setting 25 A positive balance value breaks up aluminium oxide more effectively but heats the electrode more than the workpiece the tip blunts A negative balance value increases heat generation and penetration in the base metal while decreasing oxide break up If you wish to increase electrode temperature when welding with a blunt headed electrode adjust the balance in the positive direction and if you wish to decrease electrode temperature when welding with a sharp electrode adjust the balance correspondingly in the negative direction At the factory setting the electrode tip remains almost sharp A sharp electrode allows welding with a narrower arc achieving a narrower weld and deeper penetration than with a blunted electrode Narrow welding is especially useful when fillet welding Welding with a blunted electrode produces a wide arc which also widens the area of
30. verheat indicator light is lit Power source is overheated Checkthat there is enough free space behind the machine for cooling air circulation Check cooling unit for water circulation clean cooling unit filter and air grate Add cooling liquid if necessary For further information and assistance contact your nearest Kemppi service workshop DISPOSAL OF THE MACHINE Do not dispose of electrical equipment with normal waste In observance of European Directive 2002 96 EC on waste electrical and electronic equipment and its implementation in accordance with national law electrical equipment that has reached the end of its life must be collected separately and taken to an appropriate environmentally responsible recycling facility The owner of the equipment is obliged to deliver a decommissioned unit to a regional collection centre per the instructions of local authorities or a Kemppi representative By applying this European Directive you will improve the environment and human health 19 MasterTig MLS 2300 ACDC O Kemppi Oy 1112 EN MasterTig MLS 2300 ACDC Kemppi Oy 1112 EN 5 20 ORDERING NUMBERS Power source Mastertig MLS 2300 ACDC Panels ACS ACX Cabels Welding cable 16 mm 5m Welding cable 25 mm 5m Welding cable 25 mm 10m Welding cable 35 mm 5m Earth cable 16 mm 5m Earth cable 25 mm 5m Earth cable 25 mm 10m Earth cable 35 mm 5m Torches TTC 160 4m TTC 160 8m TTC 160 16m TTC
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