Kemppi MasterTig 235ACDC GM User manual

MasterTig 235ACDC, 325DC, 335ACDC, 425DC
Operating manual - EN
MasterTig 235ACDC, 325DC, 335ACDC,
425DC
MasterTig Cooler M
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MasterTig 235ACDC, 325DC, 335ACDC, 425DC
Operating manual - EN
CONTENTS
1. General 4
1.1 Equipment description 5
2. Installation 7
2.1 Installing mains plug 8
2.2 Installing control panel 9
2.3 Installing cooling unit 10
2.4 Installing particle filter (optional) 12
2.5 Mounting units on cart (optional) 13
2.6 Connecting TIG torch 15
2.7 Connecting earth return cable and clamp 16
2.8 Connecting MMA electrode holder 17
2.9 Installing remote control 18
2.10 Installing 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 29
3.2.2 Start & stop sequence 29
3.2.3 Settings 32
3.3 Operating control panel MTP35X 35
3.3.1 Home view 36
3.3.2 Weld Assist view 37
3.3.3 Memory channels view 40
3.3.4 Start & stop sequence view 41
3.3.5 Pulse view 44
3.3.6 Current mode view 45
3.3.7 Settings view 46
3.3.8 Info view 49
3.3.9 Screen saver 50
3.4 Operating cooling unit 52
3.5 Remote control 53
4. Maintenance 54
4.1 Disposal 56
5. Troubleshooting 57
5.1 Error codes 59
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MasterTig 235ACDC, 325DC, 335ACDC, 425DC
Operating manual - EN
6. Technical data 61
6.1 Power source MasterTig 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 processes and features 72
6.8 Symbols used 78
7. Ordering codes 81
7.1 Accessories 82
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MasterTig 235ACDC, 325DC, 335ACDC, 425DC
Operating manual - EN
1. GENERAL
These instructions describe the use of Kemppi's MasterTig 235ACDC, 325DC, 335ACDC and 425DC welding power
sources designed for demanding industrial use. The full system consists of MasterTig power source with either DC
(MTP23X) or AC/DC (MTP33X, MTP35X) control panel, optional MasterTig Cooler M water cooler, optional transport unit
and Flexlite TX TIG welding torch.
For the symbols used in this documentation, refer to "Symbols used" on page78.
Important notes
Read the instructions through carefully. For your own safety, and that of your working environment, pay particular atten-
tion to the safety instructions delivered 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 instructions.
Note: Gives the user a useful piece of information.
Caution: Describes a situation that may result in damage to the equipment or system.
Warning: Describes a potentially dangerous situation. If not avoided, it will result in personal damage or fatal injury.
DISCLAIMER
While every effort has been made to ensure that the information contained in this guide is accurate and com-
plete, no liability can be accepted for any errors or omissions. Kemppi reserves the right to change the spe-
cification 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.
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MasterTig 235ACDC, 325DC, 335ACDC, 425DC
Operating manual - EN
1.1 Equipment description
Kemppi MasterTig 235 AC/DC, 325 DC, 335 AC/DC and 425 DC welding equipment is designed for professional industrial
use, with characteristics especially suitable for welding materials like aluminum and stainless steel. The equipment con-
sists of power source, control panel and cooling unit (optional). The MasterTig Cooler M cooling unit is used in liquid-
cooled TIG welding with MasterTig power source. The multipurpose MasterTig power sources are suitable for MMA weld-
ing, TIG welding and pulsed TIG welding with both direct current (DC) and, depending 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, generator compatible (300 A DC) *
•MasterTig 325DC GM, multi-voltage and generator compatible (300 A DC)
•MasterTig 335ACDC (300 A AC/DC)
•MasterTig 335ACDC G, generator compatible (300 A AC/DC) *
•MasterTig 335ACDC GM, multi-voltage and generator compatible (300 A AC/DC)
•MasterTig 425DC G, generator compatible (400 A DC) *
* A dedicated VRD(Voltage Reduction Device)model version, where the VRD function is locked on, is also available.
Control panels:
•MTP23X control panel (DC, membrane panel)
•MTP33X control panel (AC/DC, membrane panel)
•MTP35X control panel (AC/DC, 7" TFT LCD display panel).
Equipment:
1. MasterTig 235/325/335/425 power source
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MasterTig 235ACDC, 325DC, 335ACDC, 425DC
Operating manual - EN
2. MasterTig Cooler M (optional)
3. TIG torch
4. Electrode holder
5. Earth return cable and clamp
6. Remote control (wired or wireless)
7. Foot pedal remote control (wired or wireless)
8. Power ON/OFFswitch.
Connections:
a. External remote control connector
b. TIG welding cable connector (connection type R1/4)
c. Control cable connector
d. DIX connector (-)
e. DIX connector (+)
f. Coolant liquid inlet and outlet (color-coded)
g. Gas hose connection
h. Mains 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 location on the device. It is
important to make correct reference to the serial number of the product when ordering spare parts or making
repairs for example.
Quick Response (QR) code
The serial number and other device-related identification information may also be saved in the form of a QR
code (or a barcode) on the device. Such code can be read by a smartphone camera or with a dedicated code
reader device providing fast access to the device-specific information.
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MasterTig 235ACDC, 325DC, 335ACDC, 425DC
Operating manual - EN
2. INSTALLATION
Do not connect the equipment to the mains before the installation is complete.
Do not attempt to move or hang the equipment mechanically (e.g. with a hoist) from the handle on the power
source unit. The handle is meant only for manual lifting.
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 the machine vicinity.
Before installation
•Make sure to acknowledge and follow the local and national requirements regarding installation and use of high
voltage units.
•Check the contents of the packages and make sure the parts are not damaged.
•Before you install the power source on site, see the requirements for the mains cable type and fuse rating given in
the "Technical data" on page61 chapter.
Do not connect the machine to the mains before the 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 to public low-voltage sys-
tems.
MasterTig 325DC and 335ACDC: Provided that the public low voltage short circuit power at the point of common
coupling is higher than or equal to the value stated on the list below, this equipment is compliant with IEC 61000-3-
11 and IEC 61000-3-12 and can be connected to public low voltage systems. It is the responsibility of the installer or
user of the equipment to ensure, by consultation with the distribution network operator if necessary, that the system
impedance complies with the impedance restrictions.
•MasterTig 325DC and 335ACDC: 1.7 MVA
•MasterTig 325DC G and 335ACDC G: 1.9 MVA
•MasterTig 325DC GM and 335ACDC GM: 1.4 MVA
•MasterTig 425DC G: 2.0 MVA
According to the EMC classification (Class A), the MasterTig 235, 325, 335 and 425 equipments are not intended to be
used in residential locations where the electrical power is provided by the public low-voltage supply system.
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MasterTig 235ACDC, 325DC, 335ACDC, 425DC
Operating manual - EN
2.1 Installing mains plug
Only an authorized electrician is allowed to install the mains cable and 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
(MasterTig 235ACDC) the plug is pre-installed. Refer also to "Technical data" on page61 for power source specific tech-
nical information.
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MasterTig 235ACDC, 325DC, 335ACDC, 425DC
Operating manual - EN
2.2 Installing control panel
Tools:
•Screwdriver, Torx head (T20).
1. Connect the control panel’s cable and mount the control 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 together with the hinged panel cover in place with the screw provided.
The hinged panel cover and the control panel are secured with the same screw.
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MasterTig 235ACDC, 325DC, 335ACDC, 425DC
Operating manual - EN
2.3 Installing cooling unit
Only an authorized electrician is allowed to install the cooling unit.
Do not connect the equipment to the mains before the installation is complete.
Do not attempt to move the power source with a hoist from its handle. The handle is meant for manual lifting 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 the cooling unit so that the bar in the rear goes into the rear connection interface
and lower the front onto the front connection interface. Secure the power source from the front with the screws
provided.
Ensure that the cooling unit’s connection cables don't get caught between the units and get damaged in the process.
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MasterTig 235ACDC, 325DC, 335ACDC, 425DC
Operating manual - EN
3. Connect the cooling unit cables 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 contact with skin or eyes. In case of an injury, seek for medical advice.
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MasterTig 235ACDC, 325DC, 335ACDC, 425DC
Operating manual - EN
2.4 Installing 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 the air inlet on the rear of the power source.
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MasterTig 235ACDC, 325DC, 335ACDC, 425DC
Operating manual - EN
2.5 Mounting units on cart (optional)
There are three different transport unit options available for use with MasterTig welding equipment:undercarriage
P43MT, 4 wheel cart P45MT and 2 wheel cart T25MT.
Tools:
•Allen key set.
1. Assemble the transport unit according to the instructions delivered with 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 top of the cart so that the bar in the rear goes into the rear connection interface and lower the
front onto the front connection interface. Secure the power source from the front with the screws (2 x M5x12)
provided.
Do not attempt to move the power source with a hoist from its handle. The handle is meant for manual lifting only.
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MasterTig 235ACDC, 325DC, 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) .
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MasterTig 235ACDC, 325DC, 335ACDC, 425DC
Operating manual - EN
2.6 Connecting TIG torch
Gas-cooled TIG torch:
1. Assemble the TIG torch according to the instructions delivered with the torch.
2. Connect the TIG torch cables to the power source. Secure by turning the connectors clockwise.
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 delivered with the torch.
2. Connect TIG torch cables and the water cooling inlet and outlet hoses to the units. Secure by turning the con-
nectors clockwise.
The water cooling connectors are color-coded.
Tip: For Kemppi welding torches, refer also to userdoc.kemppi.com.
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MasterTig 235ACDC, 325DC, 335ACDC, 425DC
Operating manual - EN
2.7 Connecting earth return cable and clamp
Keep the work piece connected to earth to reduce the risk of injury to users or damage to electrical equipment.
With the MasterTig 235ACDC and 335ACDC power sources, always connect the 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 the clamp's contact surface is as large as possible.
DC = MasterTig 325DC and 425DC
ACDC = MasterTig 235ACDC and 335ACDC.
With the DC power source, in MMA welding only, the earth return cable can also be connected to the negative (-) con-
nector, depending on the application.
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MasterTig 235ACDC, 325DC, 335ACDC, 425DC
Operating manual - EN
2.8 Connecting MMA electrode holder
1. Connect the MMA electrode holder to the (+) connector on the power source.
2. Connect 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 large as possible.
With the DC power source, in MMA welding only, the cables can also be connected the other way round, depending
on the welding polarity.
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MasterTig 235ACDC, 325DC, 335ACDC, 425DC
Operating manual - EN
2.9 Installing remote control
Remote controls are optional. To enable remote operation, set the Remote control mode in the control panel settings.
For MTP23X and MTP33X control panels, refer to MTP23X/33X "Settings" on page32 and for MTP35X control panel, refer
to MTP35X "Settings view" on page46.
When the Remote mode is selected on the control panel, and both, wireless and wired, remotes are connected, the
wired 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 the remote control battery holder out. Install the batteries (3 x AAA) and put the holder back into the remote.
2. Turn on the Wireless remote in the control panel settings. For MTP23X and MTP33X control panels, refer to
MTP23X/33X "Settings" on page32 and for MTP35X control 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
remote.
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MasterTig 235ACDC, 325DC, 335ACDC, 425DC
Operating manual - EN
4. Once connected, the blue LED on the left of the connection button is lit. The green LED blinks when the battery is
low.
5. To enable remote operation, 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 battery holder and in the remote for the correct positioning of batteries.
1. Take the foot pedal battery holder out. Install the batteries (3 x AAA) and put the holder back into the foot pedal.
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MasterTig 235ACDC, 325DC, 335ACDC, 425DC
Operating manual - EN
2. Turn on the Wireless remote in the control panel settings. For MTP23X and MTP33X control panels, refer to
MTP23X/33X "Settings" on page32 and for MTP35X control 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 blue LED next to the button is lit. The green LED blinks when the battery is low.
Tip: You can set minimum and maximum values for the remote current adjustment in the control panel settings.
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