MasterTig 235ACDC, 325DC, 335ACDC, 425DC
Operating manual - EN
MasterTig 235ACDC, 325DC, 335ACDC,
425DC
MasterTig Cooler M
© Kemppi
1
1920900 / 2052
Page 1: ...MasterTig 235ACDC 325DC 335ACDC 425DC Operating manual EN MasterTig 235ACDC 325DC 335ACDC 425DC MasterTig Cooler M Kemppi 1 1920900 2052...
Page 2: ...ling gas bottle 21 2 11 Installing gas bottle on cart 22 2 12 Moving equipment by lifting 23 3 Operation 25 3 1 Operating power source 26 3 2 Operating control panels MTP23X and MTP33X 27 3 2 1 Home 2...
Page 3: ...235ACDC 62 6 2 Power source MasterTig 325DC 64 6 3 Power source MasterTig 335ACDC 66 6 4 Power source MasterTig 425DC 68 6 5 Cooling unit MasterTig Cooler M 70 6 6 TIG guide tables 71 6 7 Welding pro...
Page 4: ...with the equipment Items in the manual that require particular attention in order to minimize damage and harm are indicated with the below symbols Read these sections carefully and follow their instru...
Page 5: ...ing on the model selected altern ating current AC Available power source models MasterTig 235ACDC GM multi voltage and generator compatible 230 A AC DC MasterTig 325DC 300 A DC MasterTig 325DC G gener...
Page 6: ...ins cable i Cooling unit connection j Empty holder for unused DIX connector EQUIPMENT IDENTIFICATION Serial number Serial number of the device is marked on the rating plate or in another distinctive l...
Page 7: ...e installation is complete Only an authorized electrician is allowed to install the mains cable Distribution network MasterTig 235ACDC This equipment complies with IEC 61000 3 12 and can be connected...
Page 8: ...nd plug Do not connect the machine to the mains before the installation is complete Install the 3 phase plug according to the MasterTig power source and site requirements In the 1 phase power source M...
Page 9: ...ontrol panel in place Insert the top of the panel in the slot first and then lower the bottom of the panel down Push the bottom of the panel firmly so that it locks in place 2 Secure the control panel...
Page 10: ...only When a transport cart is used refer also to Mounting units on cart optional on page 13 Tools Screwdriver Torx head T20 1 Remove the power source s rear cover 2 Move the power source on top of th...
Page 11: ...les and put the rear cover back 4 Fill the cooling unit with cooling liquid MasterTig Cooler M tank volume is 3 litres and the recommended coolant is MPG 4456 Kemppi mixture Avoid cooling liquid conta...
Page 12: ...ing particle filter optional The optional particle filter is installed together with an additional filter frame as a pack 1 Place the filter into the filter frame 2 Install the filter pack in front of...
Page 13: ...it With the T25MT cart the welding equip ment securing bracket is attached once the welding equipment is installed on the cart Transport units from left to right P45MT T25MT P43MT 2 Move the unit on...
Page 14: ...5DC 335ACDC 425DC Operating manual EN With the 2 wheel cart T25MT an additional securing bracket is attached to the power source handle Secure the bracket to the cart with the screws provided M8x16 Ke...
Page 15: ...Water cooled TIG torch The cooling unit must already be installed and in place at this stage Refer to Installing cooling unit on page 10 1 Assemble the TIG torch according to the instructions delivere...
Page 16: ...e earth return cable to the negative connector 1 Connect the earth return cable to the power source 2 Ensure the earth return clamp is secured tightly to the work piece or work surface 3 Ensure that t...
Page 17: ...nect the earth return cable to the connector on the power source 3 Ensure the earth return clamp is secured tightly to the work piece or work surface 4 Ensure that the clamp s contact surface is as la...
Page 18: ...ed remote will be used Refer to the and signs on the battery holder and in the remote for the correct positioning of batteries Tools Screwdriver Torx head T15 Wireless hand remote control HR45 1 Take...
Page 19: ...select Remote mode in the control panel settings Remote control with cable HR43 FR43 1 Connect the remote control cable to the power source Wireless foot pedal FR45 Refer to the and signs on the batte...
Page 20: ...ontrol panel refer to MTP35X Settings view on page 46 3 Keeping the wireless remote close to the power source long press 3 sec the wireless remote pairing button on the foot pedal 4 Once connected the...
Page 21: ...l min If the gas flow is not correctly set this will increase the risk of defects in the weld weld porosity Spark ignition becomes more difficult if the gas flow is too high Contact your local Kemppi...
Page 22: ...ier gas bottle mounting 2 Move the gas bottle onto the rack With P45MT tilt the gas bottle back and pull the cart towards the gas bottle and push the top of the gas bottle forwards The pivot plate ass...
Page 23: ...ical hoist when the equipment is installed securely on the cart If a gas bottle is installed on cart DO NOT attempt to lift the cart with the gas bottle in place DO NOT attempt to lift the equipment w...
Page 24: ...ACDC 325DC 335ACDC 425DC Operating manual EN 2 wheel cart T25MT 1 Ensure that the welding equipment is properly secured to the cart 2 Connect the hoist hook to the lifting handle on the cart Kemppi 24...
Page 25: ...isconnect the mains plug from the mains Do not use the mains plug as a power ON OFF switch Always check before use that interconnecting cable shielding gas hose earth return cable clamp and mains cabl...
Page 26: ...rce ON The power switch is located in the rear 2 Depending on your control panel type wait approximately 15 seconds for the system to start up For control panel operation refer to Operating control pa...
Page 27: ...tment values are shown on the digital display embedded in the control panel Control panel MTP33X on the left and control panel MTP23X on the right 1 Control knob In home mode this adjusts the welding...
Page 28: ...utton Settings menu content depends on the currently selected welding process and mode 11 Home button Returns you to the initial work mode where the welding current A can be adjusted Lights and symbol...
Page 29: ...e is selected the welding current can be adjusted by turning the control knob To adjust welding current 1 Press the Home button 11 2 Turn the control knob 1 to adjust the current Current A is shown on...
Page 30: ...mode 2 Press the Pulse mode selection button 7 to switch between Pulse modes 3 Press the Start stop button 9 to enter the parameter settings 4 Browse to the AC or Pulse settings in the parameter menu...
Page 31: ...n is turned on Upslope Min Max 0 0 s 5 0 s 0 1 s step Default 0 0 s Downslope Min Max 0 0 s 15 0 s 0 1 s step Default 0 1 s Post gas Min Max 0 0 s 30 0 s Auto 0 1 s step Default Auto Adjustable parame...
Page 32: ...turning the control knob 1 3 Select a parameter for adjustment by pressing the control knob button 1 4 Adjust the selected parameter by turning the control knob 1 5 Close the parameter setting by pres...
Page 33: ...imit max Wireless remote Cancel Start Start pairing Water cooler OFF Auto ON Default Auto Weld data time OFF 1 s 10 s step 1 s Default 5 s Display off 5 min 120 min step 1 min Default 5 min Date Date...
Page 34: ...efault 0 Current freezing OFF ON Default OFF AC phase swap current 5 A 20 A Auto Info Machine type serial number Software version Power source and control panel software version number Factory reset C...
Page 35: ...sts the selected parameter s value The control knob functions also as a push button when the green light is lit in the knob center Used to navigate through the control panel views and selections 2 Men...
Page 36: ...view Home view is the control panel work mode after the initial machine and control panel start up When in Home view the welding current can be adjusted directly by turning the control knob Depending...
Page 37: ...only when powering up In case the network voltage changes the power source must be turned off and on again e VRD voltage reduction device VRD symbol on VRD is on This is always on in power source mode...
Page 38: ...int corner joint edge joint lap joint fillet joint tube joint tube plate joint The welding position PA PB PC PD PE PF PG With MasterTig DC power sources the aluminum Al selection is not available as a...
Page 39: ...modified as per normal for the actual welding Weld Assist gives you a recommendation for these Shielding gas flow Argon l min and Helium l min Electrode Diameter Filler if used Material and diameter...
Page 40: ...sets the following parameters for you Current Depends on the machine used Hot start Arc force Arc break DC indicates polarity in this case the electrode holder is connected to the positive DIX connec...
Page 41: ...trol knob 1 to highlight a channel 2 Open the channel actions menu by pressing the control knob button 1 The available actions are shown Cancel Save changes Save to and Delete 3 Select an action with...
Page 42: ...es Parameter Value Note Trigger logic 2T 4T 4T LOG 4T LOG Minilog Default 2T Welding mode Continuous Spot MicroTack Welding current Default 50 A Ignition mode Lift TIG High frequency HF ignition Adjus...
Page 43: ...st gas 0 1 s 30 0 s AUTO 0 1 s step Default Auto Adjustable parameters in MicroTack welding Parameter Value Note Pre gas 0 0 s 10 0 s Auto 0 1 s step Default Auto MicroTack spot time 1 ms 200 ms step...
Page 44: ...ngs are visible but not adjustable When Manual is selected pulse settings are visible and adjustable Average current Min Current limit min Max Machine specific These values depend also on other pulse...
Page 45: ...meter by turning the control knob 1 5 Close the parameter setting by pressing the control knob 1 Adjustable parameters Parameter Value Current mode DC DC AC MIX AC Waveform Sine Optima Square Default...
Page 46: ...ible or not visible in the settings menu accordingly Common welding settings Parameter Value Note Welding process TIG MMA Default TIG Selecting a welding process changes auto matically to the last act...
Page 47: ...step 10 ms Default Auto Negative ignition current ACDC 100 300 Auto Step 1 Default Auto Ignition current DC 100 300 Auto step 1 Default Auto Negative ignition time ACDC 0 ms 950 ms Auto step 10 ms Def...
Page 48: ...n saver image can be used For more information refer to Screen saver on page 50 Screen saver time OFF 1 min 120 min step 1 min Default 5 min Date Date setting DD MM YYYY Time 24h Time setting HH MM La...
Page 49: ...Info view you can see information about the equipment usage as well as software version for example Included in the Info view Usage counters Error status and error log Latest welds Power source type a...
Page 50: ...oad edit and download the new screen saver image onto a USB memory stick 3 Detach the control panel from the power source Remove the top screw and panel cover First pull the top of the control panel s...
Page 51: ...n the USB memory stick you want to use as a screen saver 6 Remove the USB memory stick and install the control panel back in place Refer to Installing control panel on page 9 for more information To d...
Page 52: ...ling unit s front This activates a pump motor which pumps the cooling liquid into the hoses and to the welding torch 3 Observe the cooling system throughout the cooling liquid circulation process The...
Page 53: ...Hand remote control To adjust the welding current turn the knob on the remote control Tip The remote control comes equipped with a handy clip for hanging the remote onto your belt Foot pedal remote c...
Page 54: ...vers and components are intact Check all the cables and connectors Do not use them if they are damaged For repairs contact Kemppi at www kemppi com or your dealer Periodic maintenance Only an authoriz...
Page 55: ...ectors and switches Checkup of all electric connections Checkup of the power source mains cable and plug Repair of defective parts and replacement of defective components Maintenance test Test and cal...
Page 56: ...al and electronic equipment and their 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...
Page 57: ...maximum current the lower one of these is the maximum current that can be used Make sure the coolant circulation is working normally see the coolant circulation warning LED on the power source Measure...
Page 58: ...235ACDC 325DC 335ACDC 425DC Operating manual EN Check that the welding torch is not overheating Check that the earth return clamp is properly attached to a clean surface of the workpiece Kemppi 58 192...
Page 59: ...act Kemppi service 26 Cooling liquid not circulating No cooling liquid or circulation is blocked Check the liquid level in the cooler Check hoses and connectors for blockage 27 Cooler not found Coolin...
Page 60: ...asterTig 235ACDC 325DC 335ACDC 425DC Operating manual EN 250 Internal memory failure Memory communication failed Restart welding system If problem persists contact Kemppi service Kemppi 60 1920900 205...
Page 61: ...source MasterTig 235ACDC on the next page Power source MasterTig 325DC on page 64 Power source MasterTig 335ACDC on page 66 Power source MasterTig 425DC on page 68 Cooling unit MasterTig Cooler M on...
Page 62: ...TIG 170 A 16 8 V 170 A 16 8 V 37 MMA 180 A 27 2 V 180 A 27 2 V 60 MMA 150 A 26 V 150 A 26 V 100 MMA 120 A 24 8 V 120 A 24 8 V Rated maximum output at 40 C 110 V Duty cycle and process specified in the...
Page 63: ...X MTP33X MTP35X 1 Remote controls HR45 FR45 1 Transmitter frequency and power 2 4 GHz Bluetooth 2400 2483 5 MHz 10 dBm 2 4 GHz Bluetooth 2400 2483 5 MHz 10 dBm Wired communication type Remote Analog A...
Page 64: ...22 V 60 TIG 230 A 19 2 V 230 A 19 2 V 230 A 19 2 V 100 TIG 190 A 17 6 V 190 A 17 6 V 190 A 17 6 V 40 MMA 250 A 30 V 250 A 30 V 250 A 30 V 60 MMA 230 A 29 2 V 230 A 29 2 V 230 A 29 2 V 100 MMA 190 A 2...
Page 65: ...emote Bus Kemppi Remote Bus Arc striking voltage 5 11 kV 5 11 kV 5 11 kV Stick electrode diameters mm 1 6 6 0 mm 1 6 6 0 mm 1 6 6 0 mm TIG welding cable con nection type R1 4 R1 4 R1 4 Standards IEC 6...
Page 66: ...00 A 22 V 60 TIG 230 A 19 2 V 230 A 19 2 V 230 A 19 2 V 100 TIG 190 A 17 6 V 190 A 17 6 V 190 A 17 6 V 40 MMA 250 A 30 V 250 A 30 V 250 A 30 V 60 MMA 230 A 29 2 V 230 A 29 2 V 230 A 29 2 V 100 MMA 190...
Page 67: ...pi Remote Bus Kemppi Remote Bus Arc striking voltage 5 11 kV 5 11 kV 5 11 kV Stick electrode diameters mm 1 6 6 0 mm 1 6 6 0 mm 1 6 6 0 mm TIG welding cable con nection type R1 4 R1 4 R1 4 Standards I...
Page 68: ...A 21 2 V 40 MMA 350 A 34 V 60 MMA 320 A 32 8 V 100 MMA 270 A 30 8 V Range of output TIG 3 A 1 V 400 A 41 V MMA 10 A 10 V 350 A 42 V Power factor 400 V MMA 350 A 34 V 0 91 Efficiency 400 V MMA 280 A 3...
Page 69: ...4 Standards IEC60974 1 3 10 IEC 61000 3 12 AS 60974 1 2006 3 GB 15579 1 1 In AU power source models with the Voltage Reduction Device VRD function locked on only this value is applicable 2 NO These de...
Page 70: ...g power at 1 l min 0 9 kW Cooling power at 1 6 l min 1 0 kW Recommended coolant MPG 4456 Kemppi mixture Coolant pressure max 0 4 MPa Tank volume 3 0 l Operating temperature range 20 40 C Storage tempe...
Page 71: ...C Electrode WC20 Gas nozzle Gas flow rate Min A Max A mm number mm l min Argon 15 90 1 6 4 5 6 6 5 8 0 9 5 6 7 20 150 2 4 6 7 9 5 11 0 7 8 30 200 3 2 7 8 10 11 0 12 5 16 8 10 40 350 4 0 10 11 16 17 5...
Page 72: ...ernates rapidly between pos itive and negative Used especially in aluminum welding AC Waveform Function to change the wave form of the alternating current in AC TIG welding Three options are available...
Page 73: ...current is pulsed in two different frequencies slow and fast The fast fre quency makes the arc more focused and the slow frequency produces a nice fish scale appearance to welds Downslope Welding fun...
Page 74: ...y channel Place to store predefined welding parameter settings A welding machine can include a number of preset channels Users can create new channels for their own welding jobs and modify or delete t...
Page 75: ...e positive ignition with TIG Positive ignition current Adjusts the current level of the positive ignition sequence Only in ACDC power sources TIG Positive ignition time Adjusts the length of the posit...
Page 76: ...ls with tack welds for example joining thin sheets with low heat input Startup level The point of welding current where the upslope begins T Tail arc Welding function that allows using a brief low cur...
Page 77: ...lope time is preset by the user The value zero means the function is off V VRD voltage reduction device A safety device used in welding equipment to reduce the open circuit voltage to maintain below a...
Page 78: ...N 6 8 Symbols used Symbol Description Coolant output Gas input Gas output DPulse Double pulse Carbon arc gouging TIG TIG HF ignition TIG Contact ignition TIG Water Cooling TIG Gas Cooling MIG MMA Arc...
Page 79: ...pslope Crater Fill with Downslope Crater Fill with Downlevel Tail arc Minilog 2T 4T 4T LOG 4T LOG Minilog MicroTack welding Continuous welding Spot welding Gas test Frequency or Wavelength Base curren...
Page 80: ...ptima Remote control Remote control in TIG torch Foot pedal High voltage Low voltage Common symbols used in Kemppi documentation Symbol Description User manual CE mark EMC Class A Electrical and elect...
Page 81: ...enerator use MT335ACDCG Power source 300 A AC DC generator use VRD locked on MT335ACDCGAU MasterTig 335ACDC GM Power source 300 A AC DC generator and multi voltage use MT335ACDCGM MasterTig 425DC G Po...
Page 82: ...TX 305WF TX305WF4 TX305WF8 TX305WF16 Flexlite TX 255WS TX255WS4 TX255WS8 TX255WS16 Flexlite TX 355W TX355W4 TX355W8 TX355W16 Flexlite TX 135GFN TX135GFN4 TX135GFN8 Flexlite TX 165GFN TX165GFN4 TX165GF...
